Conveyor safety requirements

Conveyors and adjacent danger zones must be guarded to protect employees from contact with moving parts. See 1917.48(a)(1) for the basic guarding requirement and 1917.48(a)(2) for required elevated walkways or suitable guarding where employees cross over or pass under conveyors.

• Guarding should prevent employee access to nip points, in-running rollers, and other moving parts.
• Provide an elevated walkway with a guardrail (or equivalent protection) where employees must cross over moving conveyors, and effective guards where employees pass beneath conveyors.

Cited regulation: 1917.48(a).

Conveyor rollers and wheels must be secured in position so they cannot move out of alignment or fall off during operation. See 1917.48(b).

• Securing can include properly tightened bearings, retaining clips, set screws, or locking mechanisms recommended by the manufacturer.
• Periodically inspect fasteners and bearings and correct loose parts immediately to prevent hazards.

Gravity conveyor sections must be firmly placed and secured to prevent them from falling. See 1917.48(c).

• Use level, stable supports and anchor points to keep sections from tipping, sliding, or separating.
• Where sections are adjustable or modular, install pins, clamps, or locks to prevent accidental movement.

Braking must be provided at the delivery end when it is necessary for safe operation to control or stop objects as they are discharged. See 1917.48(d)(1).

• Assess whether discharged items could overrun, roll, or cause hazards; if so, install brakes, chutes, stops, or impact-absorbing devices at the delivery point.
• Braking solutions should match the load type and velocity to prevent uncontrolled movement.

Electrically released brakes must be designed so they cannot be released until power is applied and must automatically engage if power fails or the control is moved to "stop." See 1917.48(d)(2).

• This means brakes should be "fail-safe" (spring-set, electrically released) so loss of power engages the brake.
• Verify wiring and control logic so the brake cannot be energized (released) without an intended power signal; test automatic engagement during maintenance checks.

Portable conveyors must be stable throughout their operating ranges and must be secured at the operating level when used at variable fixed heights. See 1917.48(e).

• Use outriggers, chocks, wheel locks, blocks, or mechanical locks to prevent tipping or shifting.
• Re-secure the conveyor any time its height or angle is changed before operating it again.

Readily accessible emergency stop controls must be provided, and conveyors that require personnel to work in the immediate vicinity must not be left unattended while running. See 1917.48(f).

• Place emergency stops where workers can reach them quickly from any point along the conveyor.
• If workers must be in close proximity to operate, inspect, or clear the line, assign a responsible person to remain at the controls; do not leave the conveyor running and unattended in those situations.

A powered conveyor must not be started until all employees are clear of it or until employees have been warned that it is about to start. See 1917.48(g).

• Use audible and/or visual warnings (bells, horns, lights) and a safe clearance procedure to ensure workers move away before start-up.
• Establish a clear start-up protocol and train employees on it.

The area around conveyor loading and unloading points must be kept clear of obstructions during conveyor operations. See 1917.48(h).

• Keep walkways, chutes, and transfer zones free of boxes, tools, debris, and loose material that could create trip hazards or jam the conveyor.
• Implement routine checks and a clearing procedure before and during operations.

Conveyors must be stopped and their power sources locked out and tagged out during maintenance, repair, and servicing, unless power is necessary for testing. See 1917.48(i)(1).

• Apply lockout/tagout following the employer's energy control procedures: isolate energy, apply locks/tags, verify zero energy before work.
• If power is needed for testing, use a defined safe procedure that minimizes worker exposure and follows appropriate controls.

The starting device must be locked out and tagged in the stop position before attempting to remove a jam or overload, unless power is necessary to remove the jam. See 1917.48(i)(2).

• If power is required to clear a jam, use a documented procedure that keeps workers clear of moving parts and provides spotters or remote controls.
• Always minimize hands-in-running-equipment work; prefer mechanical or remote jam-clearing tools when possible.

Only designated persons may operate, repair, or service powered conveyors. See 1917.48(j)(1).

• "Designated" means selected and trained by the employer to perform the tasks safely.
• Provide training, written procedures, and supervision appropriate to the complexity and hazards of the conveyor work.

Employees are directed to stay off operating conveyors and must not ride them. See 1917.48(j)(2).

• Post warnings and train employees that conveyors are not travel surfaces unless the employer has a specific, safe procedure permitting temporary use.
• Enforce the rule through supervision and disciplinary policies if necessary.

Conveyors must be operated only with all overload devices, guards, and safety devices in place and operable. See 1917.48(j)(3).

• Never bypass, remove, or defeat safety devices to keep a conveyor running.
• Tag and remove from service any conveyor with missing or inoperative safety components until repairs are completed.

Place emergency stop controls where workers can reach them quickly and always warn employees before starting a conveyor so no one is in harm's way. See 1917.48(f) and 1917.48(g).

• Locate stops at regular intervals, at conveyance infeed/outfeed areas, and at elevated walkways.
• Use clear start-up signals (audible/visual) and establish a countdown procedure to ensure all personnel are clear before energizing the conveyor.

If power is necessary for testing or to remove a jam, the work may be done with power on but only under safe, controlled procedures; otherwise, lock out and tag out the conveyor. See 1917.48(d)(1) and 1917.48(i)(1)-(2).

• When power is required, implement a written safe work procedure: keep workers clear, use guards or remote tools, have a spotter, and communicate clearly.
• When power is not needed, follow lockout/tagout steps to isolate energy before work begins.

Before starting, ensure gravity conveyor sections are firmly placed and secured and portable conveyors are stable and locked at the operating level. See 1917.48(c) and 1917.48(e).

• Check supports, anchor points, wheel chocks, and locking pins.
• Confirm rollers and wheels are secured and all guards and safety devices are in place before energizing the conveyor.

OSHA's Part 1917 requirements, including conveyor rules, do not apply to a "designated waterfront facility" used solely for bulk storage, handling, and transfer of liquids or gases as described in the 2017 Letter of Interpretation. See the LOI Applicability to waterfront facilities and 1917.

• Even though Part 1917 may not apply, employers still must address hazards under other applicable OSHA standards or the General Duty Clause if hazards are present.
• Always confirm which OSHA part applies to your specific facility and operations.

Maintenance may be performed with power on only when power is necessary for testing, and then only under safe, controlled procedures; otherwise, the conveyor must be locked out and tagged out. See 1917.48(i)(1).

• If testing requires power, use a written procedure that minimizes worker exposure, uses guards or remote devices, and employs spotters and clear communication.
• If testing does not require power, follow full lockout/tagout to isolate energy before maintenance.

Employers must designate who may operate, repair, or service conveyors and provide training so those persons can perform their duties safely. See 1917.48(j)(1).

• Training should cover start/stop procedures, emergency stops, lockout/tagout, jam-clearing procedures, hazards of moving parts, and when to stay off the conveyor.
• Keep records of training and re-train when procedures or equipment change.

Daily inspections should verify that guards are secure, rollers and wheels are fastened, emergency stops work, the area around loading/unloading points is clear, and that no safety devices are bypassed. See 1917.48(a), 1917.48(b), and 1917.48(f)-(h).

• Check for loose fasteners, worn belts, proper brake function, and accessible emergency stops.
• Tag out and remove from service any conveyor with defective safety equipment until repaired.

If an electrically released brake does not automatically engage on power loss, stop using the conveyor and repair the brake system so it is "fail-safe" as required by 1917.48(d)(2).

• Immediately take the conveyor out of service and lock/tag it out if necessary.
• Have a qualified technician correct wiring, replace faulty actuators or springs, and test the brake to ensure compliance with the fail-safe requirement before returning the conveyor to service.