Conveyor system safety requirements

Conveyors must have a means to stop the motor or engine at the operator's station and an audible warning that sounds immediately before starting. See 1926.555(a)(1) for this requirement.

• The stop control must be at the operator's station so the operator can quickly stop the conveyor.
• The audible signal must be sounded immediately before startup to warn nearby workers.
• Follow the broader conveyor requirements in 1926.555 when implementing these controls.

If the operator's station is remote, the employer must provide similar means for stopping the motor or engine at the motor or engine location. See 1926.555(a)(2).

• You must ensure workers at the motor/engine can stop the conveyor quickly in an emergency or maintenance situation.
• Consider labeling, local stop switches, or remote stop systems that are readily accessible at the drive unit.

Emergency stop switches must be arranged so the conveyor cannot be started again until the stop switch has been reset to the running or "on" position. See 1926.555(a)(3).

• This prevents a conveyor from automatically restarting after an emergency stop.
• Ensure the reset procedure is deliberate (e.g., keyed or pull-to-reset) and controlled by a trained person.
• Keep reset controls where operators or authorized personnel can access them safely.

Screw conveyors must be guarded to prevent employee contact with the turning flights. See 1926.555(a)(4).

• Guards should prevent hands, clothing, or tools from reaching rotating flights.
• Typical guards include fixed covers, interlocked access panels, or full enclosures around the shaft and flighting.
• Inspect guards regularly to ensure they remain in place and effective.

Where a conveyor passes over work areas, aisles, or thoroughfares, suitable guards must be provided to protect employees required to work below the conveyors. See 1926.555(a)(5).

• "Suitable guards" can include chutes, skirts, covers, catch pans, or overhead shields that stop or deflect falling material.
• Design and installation should prevent falling objects from striking people below and should not create new hazards.
• For detailed design and inspection guidance, follow the design and maintenance guidance referenced in 1926.555(a)(8).

All crossovers, aisles, and passageways must be conspicuously marked by suitable signs as required by Subpart G of 29 CFR 1926. See 1926.555(a)(6) and the Subpart G provisions at 1926 Subpart G.

• Signs should clearly identify hazards and required precautions (for example, "Caution: Conveyor Overhead" or "Keep Clear—Moving Machinery").
• Signs must be visible and placed where workers approach crossovers and passageways under conveyors.
• Use standardized colors and wording consistent with Subpart G guidance to ensure clarity.

Employers must lock out or otherwise render conveyors inoperable and tag them with a "Do Not Operate" tag during repairs and when operation is hazardous to employees performing maintenance work. See 1926.555(a)(7).

• Apply a positive means (lockout or equivalent) to prevent startup while work is being done.
• Use a clear, legible "Do Not Operate" tag at the control point(s) and the energy isolation points.
• Ensure only the person who applied the lock/tag or an authorized person removes it after verifying the area is safe.

All conveyors in use must meet applicable requirements for design, construction, inspection, testing, maintenance, and operation as prescribed in ANSI B20.1–1957, Safety Code for Conveyors, Cableways, and Related Equipment, per 1926.555(a)(8).

• Employers should use ANSI B20.1–1957 as the baseline for safe design and maintenance practices.
• Implement routine inspections, testing, and preventive maintenance consistent with the ANSI code.
• Keep records of inspections and repairs as part of your safety program and to demonstrate compliance.

The audible warning must be sounded immediately before starting up the conveyor. See 1926.555(a)(1).

• "Immediately before" means the warning is given right at startup to alert nearby workers.
• Employers should choose a tone/volume that is clearly heard above ambient noise and understood by workers.

Emergency stop switches must be arranged so that the conveyor cannot be restarted until reset (1926.555(a)(3)) and similar stopping provisions must be provided at the motor location if the operator is remote (1926.555(a)(2)).

• Place emergency stops where workers can reach them quickly along the conveyor and at the drive/motor.
• Design the stops so a worker cannot restart the conveyor until a deliberate reset action is taken.

Screw conveyors must be guarded to prevent employee contact with the turning flights; guarding should be in place whenever there is a potential for contact when the conveyor operates (1926.555(a)(4)).

• Guards are required to protect against contact when flights are turning, so guards should remain installed and secured unless the equipment is locked out and under controlled maintenance procedures.
• During maintenance or inspection, use lockout/tagout controls described in 1926.555(a)(7) before removing guards.

Practical suitable guards include covers, skirts, chutes, chute lips, catch pans, or overhead shields designed to stop or redirect falling material, consistent with the general requirement in 1926.555(a)(5) and the ANSI guidance cited in 1926.555(a)(8).

• Choose guards that match the material handled (dust, bulk, or large objects) and the conveyor type.
• Ensure guards are designed and maintained per ANSI B20.1–1957 as required by 1926.555(a)(8).
• Inspect guards frequently for wear, gaps, or damage that could allow falling material.

No, a "Do Not Operate" tag alone is not sufficient when it is necessary to lock out energy; conveyors must be locked out or otherwise rendered inoperable and tagged during repairs and hazardous maintenance, per 1926.555(a)(7).

• Use a physical lock or positive isolation where feasible to prevent unexpected startup.
• Tags supplement locks but should not replace a lockout where energy remains present.
• Implement a documented procedure that identifies energy sources, responsible employees, and steps to verify isolation before work begins.

Employers must assess the hazards and provide appropriate PPE based on that assessment; PPE selection should follow an employer hazard assessment and written certification when PPE will be required, as explained in OSHA's PPE hazard assessment guidance (see the OSHA interpretation at https://www.osha.gov/laws-regs/standardinterpretations/2024-03-28) and by following conveyor-specific protections in 1926.555.

• Perform a hazard assessment to identify mechanical, electrical, pinch points, falling-object, and material-dust hazards before servicing conveyors.
• Provide PPE such as gloves, cut-resistant sleeves, eye protection, hard hats, and hearing protection as determined by the assessment.
• Use lockout/tagout and confirm energy isolation per 1926.555(a)(7) before servicing moving parts.

Employers should perform and document inspection, testing, and maintenance consistent with the applicable requirements in ANSI B20.1–1957 as required by 1926.555(a)(8).

• Keep records of routine inspections, repairs, test results, and corrective actions.
• Use inspection checklists that reflect ANSI B20.1 guidance (for belts, rollers, guards, controls, and emergency stops).
• Retain documentation to demonstrate that conveyors are maintained in a safe operating condition.

Before restarting, ensure the emergency stop has been properly reset to the running or "on" position and that any maintenance or hazards have been cleared; emergency stops must prevent restart until reset (1926.555(a)(3)) and stopping means must be provided at operator or motor locations as required by 1926.555(a)(1) and 1926.555(a)(2).

• Verify all guards are replaced and secured and all tools/materials are clear of moving parts.
• Confirm any lockout/tagout devices have been removed by the authorized worker who applied them.
• Sound the required audible warning immediately before startup per 1926.555(a)(1).

Employers should train workers on safe operation, emergency stops, audible warnings, guarding, lockout/tagout practices, signage, and hazard recognition required by 1926.555.

• Train operators on how to start/stop conveyors, respond to alarms, and perform pre-operation checks.
• Train maintenance staff on lockout/tagout and the need to verify energy isolation before servicing per 1926.555(a)(7).
• Provide refresher training when procedures or equipment change or after incidents.

Signs at conveyor crossovers, aisles, and passageways should be conspicuous, use standard wording or symbols, and communicate the hazard and required precautions as required by 1926.555(a)(6) and Subpart G guidance (1926 Subpart G).

• Use clear, short phrases (for example, "Caution: Conveyor Overhead—Keep Clear" or "Authorized Personnel Only").
• Place signs where approaching workers will see them before entering the hazard area.
• Maintain signs so they remain legible and visible in all lighting and weather conditions.

Yes; overhead guards must be suitable to protect employees below and conveyors must meet the applicable design and construction requirements prescribed in ANSI B20.1–1957 per 1926.555(a)(5) and 1926.555(a)(8).

• Design guards so they prevent falling material or deflect it away from occupied areas.
• Follow ANSI B20.1–1957 for strength, clearance, and attachment details where applicable.

The employer must lock out or otherwise render the conveyor being serviced inoperable and tag it with a "Do Not Operate" tag; ensure the servicing area is isolated from other powered conveyors to prevent accidental movement, as required by 1926.555(a)(7).

• Identify and isolate all energy sources that could move the conveyor (mechanical, electrical, pneumatic, hydraulic).
• Use physical barriers or warning signs to separate the servicing area from adjacent powered conveyors.
• Ensure workers on adjacent conveyors are aware of the maintenance and the measures in place to prevent accidental startup.

The employer is responsible for assessing workplace hazards and selecting appropriate PPE; when PPE is required, the employer must perform a hazard assessment and provide a written certification that the assessment was completed, as described in OSHA's PPE hazard assessment interpretation at https://www.osha.gov/laws-regs/standardinterpretations/2024-03-28 and by applying the conveyor-specific protections in 1926.555.

• A qualified person should conduct the hazard assessment to identify mechanical, falling-object, entanglement, and noise hazards.
• The employer must document the hazard assessment (written certification) when PPE will be required and retain it as part of the safety program.
• Use the assessment to select PPE (hard hats, eye protection, hearing protection, cut-resistant gloves, etc.) appropriate to the identified hazards.