ANSI B11.12-2005 (R2020)
American National Standard
Safety Requirements for
Roll-forming and Roll-bending Machines
ANSI-Accredited Standards Developer and Secretariat:
B11 Standards, Inc.
POB 690905
Houston, TX 77269, USA
APPROVED:
REAFFIRMED:
10 May 2005
8 May 2020
by the American National Standards Institute
Board of Standards Review
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Copyright © 2020 by B11 Standards, Inc.
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AMERICAN NATIONAL STANDARD
B11.12–2005 (R2020)
AMERICAN NATIONAL STANDARDS
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AMERICAN NATIONAL STANDARD
CONTENTS
B11.12–2005 (R2020)
PAGE
FOREWORD ...........................................................................................................................................V
EXPLANATION OF THE FORMAT, AND ANSI B11 CONVENTIONS ................................................... VII
INTRODUCTION .................................................................................................................................. VIII
1
SCOPE ........................................................................................................................................... 1
1.1
1.2
1.3
1.4
GENERAL................................................................................................................................ 1
DESCRIPTIONS ....................................................................................................................... 1
INCLUDED MACHINES ............................................................................................................. 1
EXCLUDED MACHINES ............................................................................................................ 2
2
REFERENCES ............................................................................................................................... 2
3
DEFINITIONS ................................................................................................................................. 3
4
RESPONSIBILITY .......................................................................................................................... 6
4.1
4.2
4.3
5
HAZARD CONTROL ...................................................................................................................... 8
5.1
5.2
6
GENERAL.............................................................................................................................. 11
COMPONENT SELECTION...................................................................................................... 11
MACHINE CONTROLS ............................................................................................................ 11
DESCRIPTION OF MODES OF OPERATION ............................................................................. 11
ELECTRICAL EQUIPMENT ...................................................................................................... 12
VOLTAGE .............................................................................................................................. 12
PNEUMATIC AND HYDRAULIC SYSTEMS ................................................................................ 12
FLUCTUATION IN OR INTERRUPTION OF POWER SOURCES ................................................... 13
ISOLATION OF POWER SOURCES .......................................................................................... 13
STORED ENERGY.................................................................................................................. 13
INTERFERENCES .................................................................................................................. 14
PERFORMANCE OF THE SAFETY-RELATED FUNCTIONS ........................................................ 14
MACHINE INITIATION ............................................................................................................. 14
STOP AND EMERGENCY STOP CONTROLS ............................................................................ 14
OPERATOR CONTROL STATIONS .......................................................................................... 14
MANUALLY OPERATED CONTROL DEVICES ........................................................................... 15
INDICATORS.......................................................................................................................... 16
ELIMINATION OF, OR PROTECTION FROM, INHERENT HAZARDS ............................................ 17
INSTALLATION, TESTING AND START-UP ................................................................................ 18
7.1
7.2
7.3
7.4
8
TASK AND HAZARD IDENTIFICATION........................................................................................ 8
RISK ASSESSMENT / RISK REDUCTION.................................................................................. 10
DESIGN AND CONSTRUCTION .................................................................................................. 11
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
7
SUPPLIER'S RESPONSIBILITY .................................................................................................. 6
USER'S RESPONSIBILITY......................................................................................................... 7
PERSONNEL'S RESPONSIBILITY .............................................................................................. 8
GENERAL.............................................................................................................................. 18
FOUNDATION ........................................................................................................................ 18
LIGHTING .............................................................................................................................. 18
TESTING AND START-UP ....................................................................................................... 18
SAFEGUARDING ......................................................................................................................... 19
8.1
8.2
GENERAL.............................................................................................................................. 19
GUARDS ............................................................................................................................... 19
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AMERICAN NATIONAL STANDARD
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
9
B11.12–2005 (R2020)
SAFEGUARDING (PROTECTIVE) DEVICES .............................................................................. 19
AWARENESS BARRIERS, DEVICES AND SIGNS ...................................................................... 19
SAFEGUARDING METHODS ................................................................................................... 20
SAFE WORK PROCEDURES ................................................................................................... 20
COVERS AND SHIELDS.......................................................................................................... 20
COMPLEMENTARY EQUIPMENT............................................................................................. 20
SAFETY DISTANCE ................................................................................................................ 21
PERFORMANCE OF THE SAFETY-RELATED FUNCTION(S) ...................................................... 21
OPERATION AND MAINTENANCE ............................................................................................. 22
9.1
9.2
9.3
9.4
9.5
TRAINING OF PERSONNEL .................................................................................................... 22
LOCKOUT/TAGOUT/TRYOUT .................................................................................................. 23
SET-UP ................................................................................................................................. 23
OPERATION .......................................................................................................................... 23
MAINTENANCE ...................................................................................................................... 24
ANNEX A (INFORMATIVE) – EXAMPLES OF ROLL-FORMING AND ROLL-BENDING MACHINES. 25
ANNEX B (INFORMATIVE) – PERFORMANCE OF THE SAFETY-RELATED FUNCTION(S) .............. 31
ANNEX C (INFORMATIVE) – GUIDELINES FOR GENERAL TRAINING OF OPERATORS OF ROLLFORMING AND ROLL-BENDING MACHINES...................................................................................... 32
ANNEX D (INFORMATIVE) – AUDIT LIST ............................................................................................ 33
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AMERICAN NATIONAL STANDARD
B11.12–2005 (R2020)
Foreword (This Foreword is not part of the requirements of American National Standard B11.12-2005
(R2020)
The primary objective of this standard is to eliminate, control or reduce hazards to individuals associated
with roll-forming and roll-bending machines by establishing requirements for the design, construction,
operation and maintenance of these machines. To accomplish this objective, responsibilities have been
assigned to the supplier (e.g., manufacturer, modifier, rebuilder and integrator), the user, and individuals
in the working environment.
The safeguarding of production systems in roll–forming and roll–bending operations is complicated by the
wide variety of operations and operating conditions; the variations in size, speed, thickness, and the kind
of pieces to be worked; the required accuracy of the finished work; the skill of operators; the length of run;
and the method of sheet feeding and part removal. Because of these varying factors in the operations
and in the workplace, a number of point-of-operation safeguarding methods (guards and devices) have
been covered in this standard.
The words "safe" and "safety" are not absolutes. An important element of safety is attitude. While the
objective of this standard is to eliminate, control, or reduce hazards, this standard recognizes that
hazards cannot be practically reduced to zero in any human activity. This standard is not intended to
replace good judgment, proper training, or personal responsibility. Operator skill, job monotony, fatigue,
and experience are safety factors that should be considered by the user.
The original B11.12 Standard was approved in 1983 and reaffirmed in 1989 as originally written. B11.12
was then revised and approved in 1996. That (1996) standard was then revised (its third) by the B11.12
Subcommittee, processed and administered by the Secretariat, and approved by the B11 Accredited
Standards Committee for submittal to the ANSI Executive Standards Council as a newly revised
American National Standard. Approval was given May 10, 2005.
Roll-forming and roll-bending machine technology is continuously evolving. This standard reflects the
most commonly used and time-tested state of the art at the time of its approval. The inclusion or
omission of language relative to any evolving technology, either in the requirements or explanatory area
of this standard, in no way infers acceptance or rejection of such technologies.
Inquiries with respect to the application of the substantive requirements of this standard and suggestions
for its improvement are welcomed and are to be sent to the B11 Standards, Inc. – POB 690905, Houston,
TX 77269. Attention: B11 Secretariat.
EFFECTIVE DATE
The following is informative guidance only, and not a normative part of this standard. This Subcommittee
recognizes that some period of time after the approval date on the title page of this document is
necessary for suppliers and users to develop new designs, or modify existing designs or manufacturing
processes in order to incorporate the new or revised requirements of this standard into their product
development or production system.
This Subcommittee recommends that suppliers complete and implement design changes for new
machines within 30 months of the approval date of this standard.
For existing or modified machines, this Subcommittee recommends that users should confirm that the
equipment / process has tolerable risk using generally recognized risk assessment methods within 30
months of the approval date of this standard. If the risk assessment shows that modification(s) is
necessary, refer to the requirements of this standard to implement protective measures for appropriate
risk reduction.
This standard was processed and submitted for ANSI approval by the B11 Accredited Standards
Committee on Safety Standards for Machines. Committee approval of this standard does not necessarily
imply that all committee members voted for its approval. At the time this document was approved as an
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AMERICAN NATIONAL STANDARD
B11.12–2005 (R2020)
American National Standard, the ANSI B11 Accredited Standards Committee was composed of the
following member organizations:
John W. Russell, PE, CSP Chairman
Gary D. Kopps, Vice-Chairman
David A. Felinski, Secretary
Organizations Represented
Aerospace Industries Association of America
Alliance of American Insurers
Aluminum Extruders Council
American Society of Safety Engineers
AMT- The Association For Manufacturing Technology
Automotive Industry Action Group
The Boeing Company
Can Manufacturers Institute
General Motors Corporation
John Deere
Metal Building Manufacturers Association
Metal Powder Industries Federation
National Institute for Occupational Safety & Health
Occupational Safety & Health Administration
Packaging Machinery Manufacturers Institute
Precision Metalforming Association
Presence Sensing Device Manufacturers Association
Robotic Industries Association
Scientific Technologies, Inc.
Sheet Metal & Air Conditioning Contractors' Natl. Assn.
Tooling and Manufacturing Association
Toyota Motor Manufacturing North America
Name of Representative(s)
Delegate
Alternate
Will J. Wood, ARM
John Russell, PE, CSP
Melvin Mitchell
Bruce Main, PE, CSP
Russell Bensman
Ron Tillinger
Don R. Nelson
Geoffrey Cullen
Michael Taubitz
Gary D. Kopps
Charles M. Stockinger
Dennis Cloutier, CSP
John Etherton, PhD
Ken Stevanus
Charles F. Hayes
William Gaskin
Jim Kirton
Jeff Fryman
Frank Webster
Mike McCullion, CSP, ARM
Daniel Kiraly
Barry Boggs
Lance E. Chandler
Keith Lessner
Doug Hart
George Karosas, PE,
CSP Soroka
Dan
Roland Jagutis
Robert Eaker, PE CSP
Jenny Day
Dallas Gatlin
Ellen K. Blanshan
Charles E. Praeger
Teresa F. Stillman
Rick Current
Maria Ferrante
Christie Carmigiano
Mike Carlson
Roberta Nelson Shea
Chris Soranno
Roy Brown
Allan Te Ronde
Tom Huff
At the time this standard was approved, the ANSI B11 ASC B11.12 Subcommittee had the
following members:
Ashok Shah, Chairman
David Felinski, Secretary
John Bloodgood
Dennis R. Cloutier, CSP
Chris Soranno
Formtek
AMT
JFB Enterprises
Cloutier Consulting Services
STI Machine Services, Inc.
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AMERICAN NATIONAL STANDARD
Explanation of
the format, and
ANSI B11
conventions
B11.12–2005 (R2020)
This ANSI B11.12 – 2005 (R2020) standard is divided into parts
formerly referred to as sections or chapters and now referred to
as clauses in line with the current ANSI style manual. Major
divisions of clauses are referred to as subclauses and, when
referenced by other text in the standard, are denoted by the
subclause number (e.g., see 5.1).
The standard uses a two-column format to provide supporting
information for requirements. The material in the left column is
confined to “Standards Requirements” only, and is so captioned.
The right column, captioned "Explanatory Information" contains
information that the writing Subcommittee believed would help to
clarify the requirements contained in the standard. This column
should not be construed as being a part of the requirements of
this American National Standard.
As in all American National Standards, the term “SHALL”
denotes a requirement that is to be strictly followed in order to
conform to this standard; no deviation is permitted. The term
“SHOULD” denotes a recommendation, a practice or condition
among several alternatives, or a preferred method or course of
action.
Similarly, the term “CAN” denotes a possibility, ability or
capability, whether physical or causal, and the term “MAY”
denotes a permissible course of action within the limits of the
standard.
B11 conventions: Operating rules (safe practices) are not
included in either column of this standard unless they are of
such nature as to be vital safety requirements, equal in weight to
other requirements, or guides to assist in compliance with the
standard. The B11 standards do not use the term “and/or” but
instead, the term “OR” is used as an inclusive disjunction,
meaning one or the other or both. A distinction between the
terms “individual” and “personnel” is drawn. Individual includes
personnel (employees, subcontractors, consultants, or other
contract workers under the indirect control of the supplier or
user) but also encompasses persons who are not under the
direct or indirect control of the supplier or user (e.g., visitors,
vendors, etc.).
Gauge refers to a measuring or testing
instrument; gage refers to a limiting device (e.g., backgage).
Suggestions for improvement of this standard will be welcome.
They should be sent to B11 Standards, Inc.-POB 690905,
Houston, TX 77269 - Attention: B11 Secretariat.
Annexes A-D are for information purposes only.
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AMERICAN NATIONAL STANDARD
B11.12–2005 (R2020)
Introduction
The primary purpose of every machine tool is to process parts. Hazards exist that may result in injury
during production, maintenance, commissioning and de-commissioning.
The primary purpose of the ANSI B11 series of machine tool safety standards is to devise and propose
ways to minimize risks of those potential hazards. This can be accomplished either by an appropriate
machine design, by restricting personnel or other individuals’ access to hazard areas, and by devising
work procedures to minimize personnel exposure to hazardous situations. This is the essence of the
ANSI B11 series of safety standards.
The responsibility to reduce these risks to a tolerable level, or eliminate them is divided between the
equipment supplier (i.e., manufacturer, rebuilder, modifier, integrator), the equipment user and its
operating personnel. The figure below provides an overview of this standard and in particular, the
responsibilities and requirements for the supplier and user, including the user personnel.
(2) Normative References
(3) Definitions
(1) Scope
(4.1) Supplier
(4.3) User
Personnel
(4.2) User
Responsible for:
(5.1) Task and Hazard
Identification
(5.2) Risk assessment/
Risk reduction
B11.TR3
Comply with training
and safety procedures
NFPA 79
(6) Design and
Construction
B11.TR1
B11.TR4
(7) Installation, Testing
and Start-up
NFPA 70
NFPA 70E
B11.19
(8) Safeguarding
(9) Operation and
Maintenance
Note: Solid lines denote required references; dashed lines denote informative ones.
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AMERICAN NATIONAL STANDARD
B11.12–2005 (R2020)
This standard is segregated into the following clauses and attendant responsibilities (see also, the interrelationships depicted in the Introduction’s graphic):
1)
2)
3)
4)
5)
6)
7)
8)
9)
Scope – Provides the boundaries or limits of the standard (i.e., what is included and usually, what is
excluded).
Normative references – Other standards which in whole or in part, provide additional requirements when
referenced in the normative text (i.e., left-hand column of clauses 4 – 9) of this standard.
Definitions – Terms used in this standard, together with their definitions (terms are defined if they are unique,
are jargon, or used in a manner or context inconsistent with their common everyday usage or meaning).
Responsibility – The general responsibilities of the supplier, user, and the user’s personnel.
Hazard control (task/hazard identification & risk assessment/reduction) – Although clause 5 is intended to
encourage a shared responsibility between supplier and user, the requirements of this clause may fall primarily
on either entity.
Design and construction – Generally, the supplier is responsible for the entire requirements of clause 6, with
the understanding that the user may add or modify these requirements through the purchase agreement.
Installation, testing and start-up – Although predominantly the responsibility of the user, the supplier will
normally provide assistance either directly (providing personnel) or indirectly (instruction materials). The
responsibility of the supplier for layout and installation is to the extent that the user requires his involvement.
Safeguarding – This is normally a shared responsibility but often, either the supplier or the user will provide
the requirements of clause 8.
Operation and maintenance – The user is normally responsible for the requirements of clause 9, with
possible assistance from the supplier for training or documentation.
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AMERICAN NATIONAL STANDARD
B11.12–2005 (R2020)
American National Standard for Machines –
Safety Requirements for
Roll-forming and Roll-bending Machines
STANDARD REQUIREMENTS
EXPLANATORY INFORMATION
(Not part of American National Standard for machine
tools – Safety Requirements for Roll-forming and Rollbending Machines - ANSI B11.12-2005 (R2020))
1
Scope
1.1
General
E1.1
This standard specifies the safety requirements for the
design, construction, operation and maintenance (including
installation, dismantling, and transport) of roll-forming and
roll-bending machines.
For examples of roll-forming / roll-bending
machines, see Figures A.1 – A.4 (Annex A).
NOTE: In the context of this standard, the term “machine”
used without any other qualification refers to a roll-former /
roll-bender.
The terms roll-former / roll-bender, and rollforming / roll-bending machine are considered
synonymous.
1.2
Descriptions
roll-forming machines: Roll-formers are self-contained
machines normally consisting of a base, chassis, stand,
transmission drive, electrical system, tooling and lubrication
system, which are capable of continuous lineal forming of
material progressively through one or more sets of rotating
dies or rolls and associated tooling to achieve a
predetermined configuration (see Figures 1 and 2, Annex A).
roll-bending machines: Roll-benders are self-contained
machines normally consisting of a base, chassis,
transmission drive, electrical system, dies, or rolls, which are
capable of producing a bend across the width of flat or
preformed material by means of one or more rotating dies or
rolls and other tooling to achieve a predetermined
configuration (see Figures 3 and 4, Annex A).
1.3
Included machines
The requirements of this standard apply to those singlepurpose or multipurpose powered machines similar in
construction and function to roll-forming and roll-bending
machines or portions thereof, such as, but not limited to:
Roll-bending machines:
- beading machines;
- carando rolls;
- combination rotary machines;
- crimping machines;
- curling machines;
- flanging machines;
- four-roll-bending machines;
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
-
1.4
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
plate bending machines;
initial pinch rolls;
plate curving machines;
plate rolling machines;
power forming machines;
power rolls;
pyramid bending machines;
ring-rolling machines;
roll-forming machines;
slip rolls;
two-roll curving machines.
Excluded machines
The requirements of this standard do not apply to the
following types of equipment:
- assel mills;
- bar mills;
- blooming mills;
- calender mills;
- calendering rolls;
- compression bending machines;
- cross roll straightening machines;
- cutoff and slitting equipment;
- dedimpling machines;
- draw benches;
- draw bending machines;
- forging reducing rolls;
- four-slide machines;
- hot scalping pipe mills;
- ironworkers (see B11.5);
- merchant mills;
- pipe bending machines;
- plate mills;
- plug rolling mills;
- power presses (all types; see B11.1 and B11.2)
- press brakes (see B11.3);
- rotary peeling mills;
- spinning machines;
- stretch bending machines;
- swaging machines;
- thread rolling machines;
- tube bending machines (see B11.15).
2
References
This standard is intended to be used in conjunction with the
following American National Standards:
2.1
Normative references
E2.1
The following normative documents contain provisions which,
through reference in this text, constitute provisions of this
American National Standard. At the time of publication, the
editions indicated were valid. All normative documents are
subject to revision, and parties to agreements subject to this
American National Standard should consider applying the
most recent editions of the normative documents listed below.
In addition to the normative voluntary consensus
standard references, the reader should investigate
the existence of mandatory codes, specifications
or regulatory standards, e.g., those standards
found at title 29 of the Code of Federal
Regulations (OSHA standards – see also
www.osha.gov).
ANSI / ASSE Z244.1–2003, Control of hazardous energy;
Lockout/tagout and alternative methods
See also, 29 CFR 1910 Parts 147 and 333 b(2)
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
ANSI / ASME–2001, Boiler and Pressure Vessel Code,
Division 1, Section VIII
ANSI B11.19–2003, Performance Criteria for Safeguarding
ANSI / NFPA-70–2002, National Electrical Code
ANSI / NFPA-70E–2004, Electrical Safety Requirements for
Employee Workplaces
ANSI / NFPA-79–2002, Electrical Standard for Industrial
Machinery
ANSI A14.3–2002, Safety Requirements for Fixed Ladders
ANSI Z535.1–2002, Safety color code.
See also 29 CFR 1910.144, Safety color code for
marking physical hazards.
ANSI Z535.2–2002, Environmental and facility safety signs
See also 29 CFR 1910.145. Specifications for
accident prevention signs and tags.
ANSI Z535.3–2002, Criteria for Safety Symbols
ANSI Z535.4–2002, Product Safety Signs and Labels
2.2 Informative references
The following documents to the right are not normative
references, but may be helpful in conforming to the
requirements of this standard.
E2.2
ANSI B11.TR1 – 2004, Ergonomic Guidelines for
the Design, Installation and Use of Machine Tools
ANSI B11.TR3 – 2000, Risk Assessment and
Risk Reduction – A guide to estimate, evaluate
and reduce risks associated with machine tools.
ANSI B11.TR4 – 2004,
Selection of
Programmable Electronic Systems (PLC/PES) for
Machine Tools
ANSI/IEEE
compatibility
3
518–1982
Electromagnetic
Definitions
3.1
awareness barrier: An attachment that, by
physical contact, warns personnel of an approaching or
present hazard.
3.2
awareness signal: A device or signal that, by
means of audible sound or visible light, warns of a present or
approaching hazard (see awareness barrier).
3.3
bending: The application of stress concentrated at
specific points to permanently turn, press or force from a
straight, level or flat condition to a curved or angular
configuration.
3.4
control reliability: The capability of the roll-former
/ roll-bender control system, the safeguarding, other control
components and related interfacing to achieve a safe state in
the event of a failure within their safety-related functions.
E3.4 See also, safety-related function.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
3.5
device: A piece of equipment or a mechanism
designed to serve a special purpose or perform a special
function.
3.6
die(s) [roll]: the tooling used in a machine for
forming, drawing or assembling metal or other material.
3.7
drive: The source of mechanical force and energy
to impart machine motion.
3.8
emergency stop control: A control that when
actuated, initiates immediate or controlled stopping action of
hazardous motion of the machine.
3.9
guard: A barrier that prevents exposure to an
identified hazard.
3.9.1
guard, adjustable barrier: A guard with
provisions for adjustment to accommodate various
jobs or tooling set-ups.
3.9.2
guard, interlocked [barrier]: A barrier, or
section of a barrier, interfaced with the machine
control system in such a manner as to prevent
inadvertent access to the hazard.
E3.9 Also full guard, point of operation guard,
interlocked barrier guard
3.10
hazard [hazardous]: A condition or set of
circumstances that can cause physical harm to an exposed
individual.
3.11
hazard zone [area]: An area or space that poses
an immediate or impending physical hazard.
3.12 immediate stop command: A command that
initiates an action(s) to stop a hazardous motion (or situation)
at any point in the roll-former / roll-bender cycle.
3.13
inch (jog): To impart momentary motion to the
machine by manual means.
3.14
individual: A person, including personnel, who
may or may not be under the direct control of the supplier or
user.
E3.14 See also, personnel.
3.15
integrator: Any supplier that designs, provides,
manufactures or assembles a roll-forming / roll-bending
machine, or designs, provides or assembles the
safeguarding, control interfaces, interconnections or the
control system into a roll-forming / roll-bending machine.
E.3.15 See also, supplier.
3.16
E.3.16 See also, supplier.
manufacturer: Any supplier that designs,
manufactures or assembles a roll-forming / roll-bending
machine or system.
3.17
modification:
To make a change to the roll-forming / roll-bending machine
that changes its original purpose, function, capacity, operation
or safeguarding requirements.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
3.18
modifier: Any supplier that changes the original
purpose, capacity or function of the roll-forming / roll-bending
machine by design or construction.
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
E.3.18 See also, supplier and modification.
3.19
monitoring: The checking of system components
to detect a failure of a component, subassembly or module
that affects the performance of the safety-related functions.
3.20
normal stop command: A command that
initiates an action(s) to stop motion(s) or situation(s) at the
end of a roll-forming / roll-bending machine cycle or at other
points required by the machine functions.
3.21
operator: An individual who performs production
work and who controls the roll-former / roll-bender.
3.22
personnel: An individual(s) who is employed by or
on behalf of the user.
E3.22 The term ”personnel” includes subcontractors, consultants, or other contract workers
under the indirect control of the supplier or user.
3.23
pinch point: An area, excluding the point of
operation, that poses a hazard by exposure to moving parts
of the roll-former / roll-bender, its related machines or
equipment, or the material or workpieces.
3.24
point of operation: The location in the roll-former
/ roll-bender where material or a workpiece is positioned and
work is performed.
3.25
presence sensing device: A device that creates
a sensing field, area or plane to detect the presence of a part
of an individual's body.
3.26
reconstruction [rebuilding]: Restoring the rollforming / roll-bending machine or system to its original
design, purpose, capacity and function.
E.3.26 See also, supplier.
3.27
E.3.27 See also, supplier.
rebuilder: Any supplier that restores a roll-forming /
roll-bending machine to its original design, capacity, purpose,
and function.
3.28
rebuilding: Restoring the roll-forming / roll-bending
machine to its original design, purpose, capacity, or function.
NOTE - Rebuilding involves the restoration or replacement of
major components of the machine and is not considered a
maintenance or repair activity.
3.29
redundancy: The use of multiple means to
perform the same function.
3.30
safety-related function: That portion of the
control system or safeguarding device that eliminates
exposure to a hazardous situation or reduces risk to a
tolerable level.
3.31
shall: The word “shall” is to be understood as
denoting a mandatory requirement.
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3.32
should:
The word “should” is to be
understood as denoting a recommendation.
3.33
supplier:
An
individual,
corporation,
partnership or other legal entity or form of business.
NOTE - For the purposes of this standard, a supplier
provides, or makes available for use, all or part of the rollforming / roll-bending machine. When the user provides any
of the above services, the user is considered the supplier and
assumes the requirements of same.
E3.33 A supplier can be the manufacturer,
manufacturer’s agent, representative or distributor,
reseller, installer, modifier, rebuilder or integrator
who provides equipment or services for the rollforming / roll-bending machine.
3.34
tooling: Elements for guiding or imparting a
desired configuration to the material.
3.35
user: An entity that utilizes roll-forming / rollbending machines.
NOTE - When the user manufactures, installs, modifies,
rebuilds or integrates the roll-forming / roll-bending machine,
the user is considered the supplier and assumes the
requirements of same.
4
Responsibility
4.1
Supplier's responsibility
4.1.1 The supplier shall be responsible to design and
construct the machine in accordance with applicable
requirements of clauses 5, 6, and 8 of this standard.
E4.1.1 The supplier should refer to clause 2 for
applicable standards relative to the product or
service provided by that supplier. When safety
standards are not provided, safeguarding
techniques used on similar equipment should be
applied to this type of equipment, where
applicable.
4.1.2
When the user, modifier or integrator designs,
constructs or modifies the machine, the user, modifier or
integrator is considered to be the supplier of that portion of
the machine so designed, constructed or modified.
4.1.3
The supplier shall:
E4.1.3 The supplier should consult with the user
for any additional hazards that should be
considered as part of the hazard control strategy
(see clause 5).
a) identify the sources of hazards (see 5.1);
b) eliminate or provide the means for controlling the
identified hazards by implementing a risk assessment /
risk reduction strategy (see 5.2);
c) equip each machine with safeguards (e.g., guards,
protective devices) or awareness barriers/devices as
appropriate (see clause 8);
d) provide means of isolating or dissipating stored energy
associated with the machine (see 6.10);
e) furnish, in writing or by diagram, the clearances needed
by personnel for lubrication, adjustment, and similar
routine maintenance activities;
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
f) provide documentation for the equipment they provide,
including installation, testing, start-up, operation,
safeguarding and maintenance of the machine. The
system integrator, where applicable, shall ensure that
the documentation provided is coordinated and relevant
to the machine.
4.2
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
The documentation should contain the following:
•
foundation requirements;
•
power requirements;
•
equipment layout or the work envelope
including minimum clearances needed for
maintenance;
•
electrical,
hydraulic
or
pneumatic
schematics and diagrams;
•
hydraulic system pressure and flow
specifications;
•
major component weights;
•
preparation prior to start-up;
•
energy sources;
•
physical environment for which the machine
was designed;
•
lubrication and specification, including
recommended lubricants, frequency, and
locations to be lubricated;
•
function and location of operator controls,
indicators, and displays;
•
periodic maintenance, and inspection;
•
machine/tooling alignment;
•
safety precautions.
User's responsibility
4.2.1
The user shall be responsible for the overall
workplace safety of personnel.
E4.2.1 The user should provide, or require others
to provide the necessary protective measures.
The user shall review the machine design including
installation, set-up, operation and maintenance requirements
and any modifications as provided by the supplier to ensure
their conformance to applicable requirements of clauses 5, 7,
8 and 9 of this standard.
One method that may be used to identify hazards
and establish a hazard control strategy is to form a
team of individuals from the various disciplines
involved with the design, construction, operation
and maintenance of the machine.
4.2.2
The user shall ensure that:
a) The recognized hazards for the tasks to be implemented
on the machine are identified (see 5.1);
b) The protective measures required to eliminate or control
the hazards identified in 5.1 are provided and used (see
5.2);
c) A procedure for the inspection and maintenance is
established so that the machine, its guards and
protective devices are used in accordance with the
supplier’s recommendations and are in safe operating
condition and adjustment;
d) Safe working procedures are established and followed;
E4.2.2
Users should follow the supplier's
instructional material regarding the unpacking,
handling, installation, operation and maintenance
(including safeguarding) of the machine.
e)
f)
d) Additional instructional material relative to the
specific uses of the machine should be developed
and documented by the user.
The operator and auxiliary personnel follow the
instructions and directions set forth by the user to meet
the requirements of this standard (see also, E4.3);
All tooling and maintenance personnel and operators are
trained to perform the functions for which they are
responsible. The training shall include familiarizing the
employees with the portions of this standard related to
their work (see clause 9).
4.2.3
The user shall determine what personal protective
equipment is required and shall train personnel on the use of
that equipment.
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4.2.4
The user shall establish and follow a lockout/tagout
procedure that will limit personnel to exposure from
unintended machine motion that can cause injury during
repair, servicing, set–up, or adjustment of the roll-forming /
roll-bending machine (see ANSI / ASSE Z244.1).
E4.2.4 Only authorized personnel, trained and
familiar with the potential hazards of the specific
machine are to perform service and maintenance
activities.
See also, 29 CFR 1910.147 and
1910.333.
4.3
E4.3
Personnel's responsibility
Personnel shall be responsible for following the training and
safety procedures provided by the user in the operation and
maintenance of the machine, in accordance with clause 9.
The Occupational Safety and Health Act of 1970 –
Public Law 91-596, states in section 5(b), “Each
employee shall comply with occupational safety
and health standards and all rules, regulations and
orders issued pursuant to this Act which are
applicable to his own actions and conduct.”
The operator shall comply with the instructions of the user
concerning safe methods of operation of the machine.
Examples of the machine operator's or auxiliary
personnel’s responsibilities:
a) Follow all safety practices and procedures
given in this standard that apply to his/her
actions and conduct;
b) Notify their supervisor when they observe an
unsafe practice or condition;
c) Properly use all specified personal protective
equipment;
d) Install, position, or adjust safety devices as
instructed by the user under the provisions of
this standard;
e) Do not alter, remove, or disable any safety
equipment without the approval of the user;
f) Make a visual safety check of the machine
during each operating shift;
g) Maintain an orderly work area. Particular
attention should be given to the storage of
tools or other items that could be dislodged
and fall or roll.
5
Hazard control
5.1
Task and hazard identification
Reasonably foreseeable tasks and associated hazards shall
be identified throughout the lifecycle (design, installation, setup, operation and maintenance) of the machine.
E5.1
Task identification should take into account, but not
be limited to the following task categories:
•
packing and transportation;
•
unloading/unpacking;
•
machine installation;
•
start-up/commissioning;
•
operation (all modes);
•
planned maintenance;
•
unplanned maintenance;
•
major repair;
•
recovery from control failure;
•
recovery from process failure;
•
troubleshooting;
•
housekeeping;
•
decommissioning;
•
disposal.
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STANDARD REQUIREMENTS
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EXPLANATORY INFORMATION
For each of the above task categories, there may
be many tasks. Tasks are specific activities that
relate to the task category. Each task category
may have numerous tasks associated with it. For
example, for the task category “operation,” tasks
include:
•
handling raw material;
•
handling finished product;
•
handling and servicing tooling;
•
process lubrication;
•
equipment cleaning;
•
accessing finished product;
•
monitoring machine operation.
For each of the above tasks, there may be
numerous hazards. Examples of hazards and
hazardous situations are:
a) Movement (normal/abnormal):
•
raw material; loading device(s);
•
die handling devices;
•
process lubrication devices;
•
moving guards or shields;
•
power transmission devices.
b) Ignition of flammable materials:
•
hydraulic fluids;
•
process fluids.
c) Machine faults and abnormal conditions:
•
improper control data transmission;
•
component failure;
•
pressurized fluid leaks.
d) Energy sources:
•
electrical;
•
hot surfaces;
•
gravity;
•
compressed fluids;
•
accumulators;
•
springs.
e) Moving masses;
f) Pinch or shear points;
g) Hazardous materials and environments;
h) Contact with hot/cold fluids or surfaces;
i) Human error;
j) Workplace design;
k) Equipment interfaces;
l) Tooling;
m) Work area cleanliness;
n) Rotating components such as shafts or
couplings in close proximity to personnel.
Areas that require frequent maintenance or
adjustment should have:
•
catwalks or walkways with railings in
hazard zones;
•
non-slip surfaces on walkways and
catwalks;
•
ladders for access to maintenance areas
above or below the floor line.
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In addition, reasonably foreseeable hazards not directly related
to tasks shall be identified.
Following are some examples of reasonably
foreseeable hazards not related to tasks:
•
Breakage of tooling;
•
Breakage of machine components (e.g., tie
rods, cylinders and cylinder rods);
•
Loosening or fracturing of mounting bolts or
other fasteners causing hazards associated
with:
motors;
couplings;
tooling;
pumps;
valves;
piping or other stationary parts.
•
Failure of hydraulic piping, fittings,
cylinders,
accumulators,
control
components or other parts under pressure;
•
Loss or disturbance of utilities;
•
Interferences:
Electrical (EMI, ESD, RFI, etc., see
6.9);
Mechanical (shock, vibration, etc.).
Tasks and associated hazards shall be identified and
reassessed when necessary or whenever the machine is
modified or its typical use is changed (see 5.2).
For a more detailed discussion on task/hazard
combination identification, refer to ANSI B11.TR3.
5.2
E5.2
Risk assessment / risk reduction
Risks associated with the task/hazard combinations identified
in 5.1, including reasonably foreseeable hazards not directly
related to tasks, shall be assessed and reduced to a tolerable
level by incorporating one or more of the following protective
measures, in hierarchical order:
Where possible and when necessary, the user, in
conjunction with the supplier, should ensure that
the task/hazard combinations and reasonably
foreseeable hazards not directly related to tasks,
and their associated protective measures are
appropriate for the machine.
In addition, a team approach is recommended.
Although an individual may be responsible for
drafting the analysis, a team of involved personnel
(e.g., operators, maintenance, engineering, etc.)
should participate in the risk assessment and
reduction effort.
The type of protective measure is determined by
the nature of the task and associated hazard(s) for
the machine. Protective measures should be
selected to provide the desired degree of risk
reduction.
1)
2)
3)
4)
Eliminate or control the hazard(s) by design;
Control exposure to hazards by the use of guards or
safeguarding devices;
Provide other safeguarding (e.g., awareness barriers,
awareness signals and safeguarding methods);
Implement administrative controls or other protective
measures (including safe work procedures, preventive
maintenance, training, re-training, personal protective
equipment and warning signs).
2) See also, ANSI B11.19
3) See also, ANSI B11.19
4) See also, the ANSI Z535 series and B11.19.
For further information on risk assessment, see
ANSI B11.TR3.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
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EXPLANATORY INFORMATION
When performing risk reduction for task/hazard combinations
identified in 5.1, including reasonably foreseeable hazards not
directly related to tasks, the requirements of clauses 6, 7, 8
and 9 shall be implemented.
For performing risk reduction on task/hazard
combinations and reasonably foreseeable hazards
not directly related to tasks not resolved by
applying clauses 6, 7, 8 and 9, see ANSI B11.TR3.
Tolerable risk shall be determined by evaluating the
application of the protective measures against the following
factors:
Zero risk does not exist and cannot be attained.
However, a good faith approach to risk
assessment and risk reduction should reduce risk
to a tolerable level. For further information on
tolerable risk, see ANSI B11.TR3.
•
•
•
•
•
•
•
risk-reduction benefit;
technological feasibility;
economic feasibility;
ergonomic impact;
productivity;
durability and maintainability;
usability.
Risk reduction is complete when the protective measures,
consistent with this standard, are applied and tolerable risk has
been achieved for the identified task/hazard combinations and
the machine as a whole.
6
Design and construction
6.1
General
Risk-reduction benefit is determined by estimating
the potential reduction in severity of harm or
probability of occurrence of harm. The type of
protective measure is determined by the nature of
the task and associated hazard(s) for the machine
under consideration. Protective measures should
be selected to provide the desired degree of risk
reduction.
Protective measures listed in this standard appear
in clauses 6 through 9.
This clause describes the design and construction
requirements for the component elements of a roll-forming /
roll-bending machine. Where certain component elements
are not part of a specific machine, the corresponding
requirements found in the following sub clauses do not apply.
The roll-forming / roll-bending machine shall be designed and
constructed in such a manner that risks are reduced to a
tolerable level in accordance with 5.2
6.2
Component selection
All components shall be selected to have specification limits,
established by their manufacturer, equal to or greater than
any adjustable setting of the system.
6.3
Machine controls
The machine controls may be electrical, mechanical,
hydraulic, pneumatic, or in combination. The control system
shall be designed with a stopping operation that requires a
separate manual action to restart the machine.
Machine controls shall be identified as to their function.
6.4
Description of modes of operation
6.4.1
Jog mode
In the jog mode, the machine function shall be initiated by the
operator during set–up or threading the material through the
forming rolls.
E6.4.1
Jog mode may include operations in which a feed
function is initiated or engaged by the operator,
and will continue the motion until it is stopped by
the operator.
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6.4.2
Semiautomatic mode
In the semiautomatic mode, one or more functions in the work
cycle are automatically performed and sequenced, but the
operator is required to initiate some part of the cycle.
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
E6.4.2
Machines in the semiautomatic mode may move
from function to function but require the operator to
change parts or initiate the next cycle, or both.
6.4.3
Automatic mode
Machines in the automatic mode can complete a series of
functions on a part, and upon completion of a cycle, can
change parts and repeat the cycle on a subsequent part
without operator intervention.
6.5
Electrical equipment
The electrical equipment shall meet the requirements of ANSI
/ NFPA 79.
E6.5
ANSI / NFPA 79 specifies the requirements for the
system or components which are provided to
operate the machine.
Special control performance may be necessary
following the actuation of an emergency stop, for
example, as it applies to a pyramid roll-bender.
This type of machine may be equipped with an
emergency stop that both stops the machine and
drops the end frame away from the bending rolls,
allowing the release of the rolls so that they
raise/open,
releasing
potentially
trapped
individuals. This would require a Category 1
emergency stop.
6.6
Voltage
All ac operator control circuits shall be powered by not more
than a nominal 120-volt ac supply obtained from a
transformer with an isolated secondary.
Higher voltage may be necessary for operation of machine or
control mechanisms handled by the operator, but motor
starters with integral start-stop buttons may utilize line voltage
control. All dc operator control circuits shall be powered by
not more than a nominal 24 volt dc supply isolated from any
higher voltages.
When a part-sensing device is used in which the workpiece is
a conductor, the voltage shall not exceed a nominal 24 volts.
6.6.1
Grounding and shielding
The machine control system shall be protected against false
operation due to improper or accidental grounding or
improper shielding.
6.7
E6.6.1
The grounding and shielding recommendations of
the electrical equipment supplier(s) should be
considered when interconnecting various parts of
the electrical equipment (see also, ANSI/NFPA
79).
Pneumatic and hydraulic systems
6.7.1
Stopping machine operations
Where proper safe machine operation requires that supply
pressure be controlled within specific limits, an automatic
means for stopping and preventing machine operation when
the supply pressure falls below or goes above the specific
limits shall be provided.
6.7.2
Interrupting supply pressure
A means of interrupting supply pressure and safely venting
pressure stored in machine operation shall be provided. The
valve or other means provided for this function shall be
equipped with a lockout provision (see ANSI / ASSE Z244.1).
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6.7.3
Filtering and separating
Where safe operation components require control or
elimination of contaminants in the pressure-supply system,
means of filtering or separating these contaminants shall be
provided.
6.7.4
Compatibility
Working liquids or gases shall be compatible with systems
components to provide reliable and safe operation.
6.7.5
Hydro-pneumatic
accumulators
and
air
receivers.
Hydro-pneumatic accumulators and air receivers shall
conform to the ANSI / ASME Boiler and Pressure Vessel
Code.
E6.7.5
A pressure vessel is a storage tank or container for
a fluid (gas or liquid) under pressure above 100
kPa (15 psig) intended as a means of energy
storage or control, and has a cross section larger
than the system tubing or piping. In most cases,
the supplier will not actually manufacture the
pressure vessel, however, the supplier should
procure a pressure vessel that has been
manufactured according to that Code.
6.7.6
Working pressure
The maximum anticipated working pressure in any hydraulic
and pneumatic system shall not exceed the safe working
pressure of any component used in that system.
6.8
Fluctuation in or interruption of power
sources
E6.8
Fluctuations or interruptions of any of the external power
sources shall not cause hazardous motion or shall
immediately initiate stopping action of hazardous motion(s) of
the machine.
Power source monitors which initiate the stopping
action may be required.
Restoration of normal power conditions shall not in itself
initiate operation of the machine.
Restarting of normal operation shall require restoration of
normal power conditions and restarting of the machine by the
operator.
6.9
Isolation of power sources
Means for isolating power sources shall be provided, shall be
marked or labeled to identify the power source and shall have
lockout/tagout capability (see ANSI / ASSE Z244.1).
6.10
Stored energy
E6.10
Loss of power shall not result in a hazardous condition due to
the release of stored energy.
Some examples of stored energy are air or
hydraulic pressure, gravity, springs, counterbalances, flywheels,
capacitors,
and uninterruptible power supplies.
Means shall be provided for the isolation, containment or
controlled release of stored energy that can create a
hazardous condition.
Examples of isolation containment or controlled
release of stored energy are:
•
blocking;
•
pinning;
•
chaining;
•
locking;
•
controlled bleeding;
•
check valves;
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EXPLANATORY INFORMATION
•
•
•
•
6.11
Interferences
The user shall ensure that external interferences to the
control or power systems do not adversely affect the safe
operation of the machine.
discharging;
dynamic braking;
mechanical braking;
power down procedures.
E6.11
Some sources of interferences are:
•
electromagnetic interference (EMI);
•
electrostatic discharge (ESD);
•
radio frequency interference (RFI);
•
shock/vibration.
These are normally associated with the operation
of
•
air conditioners;
•
electric welders;
•
electric furnaces;
•
elevators;
•
high energy power lines;
•
RF, radar, or microwave equipment;
•
electrostatic equipment;
•
large brush type motors;
•
heavy machinery or similar equipment.
See also, ANSI / IEEE 518.
6.12
Performance of the safety-related functions
E6.12
The operation of the safety-related functions of the control
system shall meet the requirements of 8.10.
The safety-related functions of the control system
relate to sensing devices used to detect conditions
that are considered a personnel hazard and pose a
risk of injury, and are determined from the hazard
control strategy (see clause 5).
6.13
E6.13
Machine initiation
Machine initiation shall require that actuation be from a
control station(s) located outside the associated hazard
zone(s).
6.14
The supplier should consider the use of a delayed
start where an audible or visual signal of
impending start is provided. The delay should be
sufficient to allow personnel in the hazard area to
evacuate the hazard area.
Stop and emergency stop controls
6.14.1
General
Stop and emergency stop controls shall be provided and shall
be designed and constructed to meet the requirements of
ANSI / NFPA 79.
The components of the stop circuit shall be designed,
selected, constructed and interconnected in a manner to
withstand the expected operational and environmental
conditions and to ensure reliable stopping performance.
6.15
Operator control stations
Operator control stations shall be located so as to be readily
accessible to the operator from his/her normal position.
When more than one control station is provided, only one
shall be operative except for the emergency stop control.
Switching from one control station to another shall not create
a hazard.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
6.16
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
Manually operated control devices
6.16.1
General
Manually operated control devices shall be:
• readily identifiable and appropriately marked or labeled
as to their function;
• designed and installed to accommodate human
capabilities and limitations. Manually operated control
devices shall be readily identifiable and appropriately
marked or labeled;
•
readily accessible to the machine operator and be
placed to avoid reaching past moving parts that are
likely to cause injury;
•
protected from unintentional operation by normal
movement of the machine operator or work. This is
particularly applicable where such unintentional
operation can result in unexpected hazardous
conditions.
E6.16.1
Human capabilities and limitations to be addressed
can include but not necessarily be limited to:
•
work heights;
•
reaching distance;
•
strength;
•
visibility;
•
posture.
See also ANSI B11.TR1
The intent to have the machine designed so that
the machine operator is not required to reach over
or past moving parts that may be inadvertently
contacted and likely to cause injury while attention
is focused on operating the controls.
6.16.2
Means for limiting access to control devices
Means for limiting access to the initiation and selection of the
mode of operation of the machine shall be provided.
EXCEPTION: This requirement does not apply to controls
such as "Emergency Stop," where ease of access is of
primary importance.
E6.16.2
Means for limiting access can include but are not
limited to:
• location;
• design;
• key lock switch;
• access codes;
• interlocks.
6.16.3
Control designation
A control shall not initiate any motion unrelated to its
designation.
E6.16.3
The intent is to avoid startling the operator by
having a dual action occur when actuating a
control device.
6.16.4
Stop control devices
Stop controls shall be located where they can be easily
reached by the operator at the normal operating position, and
shall not require reaching into hazardous areas. They shall
be red, clearly marked, and require only momentary actuation
to deactivate the source of power.
6.16.5
Emergency stop devices
Emergency stop device(s) shall be clearly identified and shall
be located to provide easy and non-hazardous access to
individuals.
E6.16.5
Types of devices include, but are not limited to:
• mushroom type push buttons;
• cables, ropes or bars;
• handles;
• in some specific applications, foot pedals
without protective covers.
The emergency stop device shall be:
a) designed for easy operation by individuals;
b) colored red and, where possible, be on a background of
yellow.
Where required, provisions to connect additional emergency
stop devices shall be provided.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
Cables or ropes, when used as emergency stop devices,
shall meet the following additional requirements, taking into
account the following:
• the amount of deflection required to generate the
emergency stop command;
• the maximum deflection possible;
• the minimum clearance between the cable or rope and
the nearest machine component;
• the force required to actuate the emergency stop
function;
• marking of the cable or rope to ensure visibility by
individuals (e.g., by the use of marker flags).
In the event that the cable or rope breaks or becomes
disengaged, the emergency stop command shall be initiated.
Resetting facilities shall be located such that the entire length
of cable or rope is visible from the location. Where this is not
practical, individuals shall be instructed to inspect the entire
length of the cable or rope to determine the cause of the
actuation, and shall ensure that after actuation but before
resetting, all individuals are clear of the hazards.
6.16.6
Jog control devices
Jog controls, when provided, shall be designed to prevent
accidental or continuous operation.
E6.16.6
Jog control devices should be readily identifiable
from run or automatic operation controls by design
such as:
•
location;
•
color;
•
touch;
•
sight.
The use of jog bars is not recommended.
6.16.7
Run control devices
Run controls shall be used to start continuous machine
operations and shall be guarded to prevent the accidental
starting of the machine.
E6.16.7
Examples of meeting this requirement are the use
of shielded or recessed run buttons (see Figure 5,
Annex A).
6.16.8
Foot control devices
Foot-operated controls, if used, shall be protected to prevent
accidental operation from falling or moving objects or from
someone accidentally stepping on them.
E6.16.8
See Figure 6, Annex A.
6.17
E6.17
Indicators
Indicators, when provided, shall meet the following
requirements:
a) Indicators, displays, and monitors required for safety shall
be designed, constructed and located such that they
provide a recognizable signal, either visible or audible, to
the operator;
b) All indicators shall be clearly identified as to their
meaning;
c) Visual indicators shall be located such that they may be
seen by the operator when facing the hazard zone or
when the operator is in the normal operating location;
d) Audible indicators shall have a distinctive sound and
intensity such that it will be readily distinguishable from
other audible sounds or ambient noise.
c) A possible color scheme for lights used as
status indicators is found in ANSI / NFPA 79.
d) Where color blindness or hearing impairment is
a consideration, flashing lights can be an effective
method.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
6.18
Elimination of, or protection from, inherent
hazards
6.18.1 Power transmission components
Where practicable, the supplier shall eliminate the power
transmission hazard by design or provide protection against
the hazard in accordance with clause 8.
E6.18.1
Some of the hazards that can exist are the
following:
• rotating components, such as gears,
sheaves, and shafts in close proximity to
personnel;
• pinch points, such as meshing gears, belts,
and chains.
6.18.2 Powered moving components
A powered moving component that constitutes a hazard to
personnel as determined from clause 5 shall be safeguarded
in accordance with clause 8.
E6.18.2
Some of the hazards that can exist are:
• pinch points between moving and stationary
components of the machine;
• worktable extending past a stationary
structure.
6.18.3 Broken or falling machine components or
accessories
Machine components or accessories shall be designed,
secured, or covered to minimize the possibility of injury to
personnel in the event that the component or accessory
breaks, falls, or releases its mechanical energy.
E6.18.3
6.18.4 Machine mounting
The machine shall be designed, where necessary, with
provision to secure the machine to the floor or to a bench or
machine stand. The bench or stand, where necessary, shall
be provided with a means to secure it to the floor or
foundation.
E6.18.4
See also, 7.2.
Some of the hazards that can exist are those due
to the following:
• breaking of shafts, causing falling motor
sheaves, flywheels, clutches, gears, or other
moving components;
• loosening of mounting bolts, causing falling of
motors, protective covers, or other stationary
components.
The manufacturer shall indicate in the installation instructions,
the conditions under which the machine shall be secured to
the floor or foundation.
6.18.5 Access to machine components
Access to machine components shall be designed to minimize
the likelihood of slips, trips, and falls by provision of adequate
hand holds, foot holds, and where necessary, by slip–resistant
surfaces.
When provided, ladders, work platforms, and walkways shall
be in accordance with ANSI A14.3.
E6.18.5
Examples of protective measures which may be
used to satisfy this requirement are:
•
fixed railings and toe boards;
•
fixed means of access (e.g., stairways,
ladders);
•
fixed working platforms with safety railings
against the hazard of falling;
•
supports for safety belt;
•
means to attach movable ladders.
6.18.6 Contact with high-temperature surfaces
The supplier shall provide protection for machine operators in
the normal work area from coming into contact with machine
components whose surface temperatures may be in excess of
70°C (160°F).
E6.18.6
The supplier shall also provide protection for the operator(s) in
normal work areas so that he/she will not contact machine
components at temperatures in excess of 60°C (140°F) where
reaction from contact can result in an injury.
Inadvertent contact with a surface temperature in
excess of 60°C (140°F) can result in injury to the
operator due to reflexive reaction causing falls or
unintended movement into some other hazard.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
6.18.7 Contact with sharp edges, corners, and
projections
The supplier shall design and construct the machine
components without exposed sharp edges, corners, or
projections that can present a hazard upon contact.
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
E6.18.7
Edges or corners with less than 0.25 mm (0.01inch) radius are considered sharp. Particular
attention should be given to sheet metal panels,
both edges and cutouts.
6.18.8 Reaching into hazard zones
Equipment shall be provided so that the operators are not
required to reach into hazard zones to lubricate or degrease
the tools while the machine is in normal operating mode.
7
Installation, testing and start-up
7.1
General
E7.1
The user shall develop a plan for the installation of the ANSI/NFPA 70E addresses those electrical safety
machine and its associated equipment.
requirements for the workplace that are necessary
for the practical safeguarding of personnel.
The installation shall conform to:
a) applicable local, state and federal regulations, or the
authority having jurisdiction;
b) ANSI / NFPA 70;
b) ANSI/NFPA 70 specifies the requirements for the
c) ANSI / NFPA 70E;
interconnecting equipment (i.e., the wire, cable,
d) ANSI / NFPA 79, where applicable;
conduit, fittings and methods).
e) ANSI / ASSE Z244.1;
f) requirements or specifications from the supplier;
g) the requirements of this clause.
7.2
Foundation
The foundation on which the machine is to be installed shall be
capable of bearing the normal static and dynamic loads.
7.3
Lighting
E7.3
Lighting shall be installed to ensure that personnel can safely The lighting should not create shadows, excessive
perform their tasks.
glare, or stroboscopic effects.
Areas requiring
frequent inspection or maintenance should be
properly illuminated (see ANSI / IES RP7).
7.4
Testing and start-up
7.4.1
Testing and start-up review
E7.4.1
A safety review shall be conducted at the user's facility for A risk assessment can be very helpful in conducting
personnel involved in the testing and start-up prior to the start- the safety review.
up of the machine.
7.4.2
Personnel restrictions
Only assigned personnel shall be allowed to operate the
machine and its associated equipment during testing and startup.
E7.4.2
Personnel should be assigned on the basis of
experience, training, and familiarity with the
machine.
7.4.3
Safeguarding
If the operational safeguarding is not in place prior to testing
and start-up, other (alternative) safeguarding shall be provided
and used (see clause 8 and ANSI B11.19).
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
8
Safeguarding
8.1
General
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
Guards, safeguarding devices, awareness barriers, awareness
devices, shields, safeguarding methods and safe work
procedures shall meet the applicable requirements of ANSI
B11.19.
8.1.1 Guards and devices shall meet the requirements of 8.2 E 8.1.1 Where specific guards, devices, or methods
and 8.10.
are mentioned in this standard, other guards,
devices, or methods that will provide equivalent
safety results may be used.
8.1.2 The responsibility for the selection, installation and
operation of the appropriate guard, presence sensing device,
awareness barrier, awareness device, shields, safeguarding
method or safe work procedure shall be based on the risk
assessment and risk reduction strategy and shall be in
accordance with clauses 4 and 5.
E8.1.2 The user should review the recommendations
of the machine supplier and the safeguarding
manufacturer when determining the proper
safeguarding.
8.2
E8.2
Guards
The design and construction of a barrier guard shall ensure Other guards, safety devices or methods may be
that individuals cannot reach the hazard by reaching over, used in conjunction with barrier guards to
under, around, or through the barrier guard.
accomplish this requirement. The safeguarding
supplier should provide instructions to the user for
See ANSI B11.19, clause 7 for the design, construction, the proper installation and use of the barrier guard.
installation and operation requirements.
Barrier guard openings should conform to either
B11.19 Annex D, Table D.1 / Figure D.10 (more
protective) or the OSHA (29 CFR 1910.217) 0-10
table.
8.3
Safeguarding (protective) devices
Safeguarding devices shall meet the requirements of ANSI
B11.19 clause 8 for the design, construction, installation and
operation requirements.
8.4
Awareness barriers, devices and signs
8.4.1 Awareness barriers shall be designed, constructed, and
installed such that an individual cannot reach into the hazard
zone without a conscious effort and contact with the barrier.
See 9.1 of ANSI B11.19.
E8.4.1 An awareness barrier may move to allow
entry of work pieces of varying sizes, but prevents
the operator from reaching the hazard without the
operator's awareness.
In addition, the device
provides visual boundaries to the operator's
movements and indicates the hazard zone.
Operators should be made aware of the nature of
the hazards and the significance of the awareness
barrier by instructions, training, or the use of signs in
the vicinity of the hazard zone. See also, ANSI
B11.19, clause 14.
8.4.2 Awareness signals shall be designed, constructed, and
installed to provide a recognizable audible or visual signal of
an approaching or present hazard. See 9.2 of ANSI B11.19.
8.4.3 Awareness signs shall meet the requirements of ANSI E8.4.3 Operators should be made aware of the
Z535.1, Z535.2, Z535.3 and Z535.4.
nature of the hazards and the significance of the
awareness signs by instructions and training.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
8.5
Safeguarding methods
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
E8.5
When safeguarding methods are used, the user shall ensure Safeguarding methods include safe distance
that personnel are aware of the proper use. See ANSI safeguarding, safe holding safeguarding and safe
B11.19, clause 10.
opening safeguarding.
Proper training and supervision are essential to the
use of methods used to safeguard personnel.
Safeguarding other individuals should be considered
and their protection may require additional or
supplemental safeguarding. See 4.2 and 4.3 for
user and personnel responsibilities.
8.6
Safe work procedures
The user shall review the guards, safeguarding devices or
methods, and the training used to determine if safe work
procedures are required. Where required, the user shall
develop and ensure the use of safe work procedures. See
ANSI B11.19, clause 11.
E8.6
When determined to be necessary, safe work
procedures should be developed and used to ensure
that a safe work practice is implemented for the
task(s) performed.
Factors to consider in determining whether safe
work procedures are required may include, but are
not limited to, the following:
•
where tasks are complex;
•
where tasks have high risk;
•
where training, skill or work experience is
limited;
•
where other safeguarding is removed or
bypassed;
•
where required to augment other safeguarding.
8.7
Covers and shields
E8.7
When covers or shields are used to perform a safeguarding Die or tool breakage sometimes occurs in any
function, they shall meet the appropriate requirements of 8.2.
forming/bending process, causing flying objects to
exit from inside the machine. When this presents a
significant hazard to individuals, guards or other
safeguarding should be implemented based on 5.1
and 5.2.
8.8
Complementary equipment
The requirements of this section shall apply to the design,
construction, and operation of complementary equipment used
in conjunction with safeguarding described above. See ANSI
B11.19, clause 12.
E8.8
Complementary equipment is used to augment the
selected safeguarding. These may include safety
blocks, chain locks, locking pins, work handling
equipment,
enabling
devices,
process
malfunctioning and monitoring equipment, hand
tools, and safety interface devices (e.g., safety relay
modules and stop and emergency stop devices).
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
Examples of complementary equipment include, but
are not limited to:
• blocking or pinning of billet loaders or butt
shears;
• tools to handle machine tooling or remove
billets from the machine;
• pressure or force sensing devices to prevent
overloading of tooling;
• tool alignment sensing equipment;
• dummy block handling tools;
• indirect platen-hole viewing;
• tie-off equipment when working on top of the
machine;
• billet and tooling temperature control devices.
8.9
Safety distance
When required by this standard, the guard or safeguarding
device shall be located at a distance from its associated
hazard such that individuals cannot reach the hazard before
cessation of hazardous motion (or situation).
8.10
E8.9
Guards and safeguarding devices should be located
at a safety distance in accordance with ANSI
B11.19. See also, Annex A, Figure 7.
Performance of the safety-related function(s) E8.10
When a component, module, device or system failure occurs,
such that it or a subsequent failure of another component,
module, device or system would lead to the inability of the
safety-related function(s) to respond to a normal stop
command or an immediate stop command, the safety-related
function shall:
• prevent initiation of hazardous machine motion (or
situation) until the failure is corrected or until the
control system is manually reset; or
• initiate an immediate stop command and prevent reinitiation of hazardous machine motion (or situation)
until the failure is corrected or until the control system
is manually reset; or
• prevent re-initiation of hazardous machine motion (or
situation) at the next normal stop command until the
failure is corrected or until the control system is
manually reset.
This sub-clause applies to components that are
deemed critical to safe machine operation, where
component failure could result in an unsafe
condition. Examples include:
• components of the machine stop control;
• the detection device used for ensuring the
dummy block is within the container before
the application of extrusion force;
• limit sensors on gates, guards, or other
devices used to ensure safe working
distances are maintained or that protect a
hazardous area such as around die
changing equipment.
Accumulator decompression or isolation sensors
should be considered if their energy state could
create a hazardous condition.
Isolation valves
preventing motion of machine components during
normal operating service work should also be
considered if a hazardous condition could result.
Because some failures cannot be detected until the
completion of a cycle or a portion of the cycle, loss
of the safety-related function(s) may occur for a
portion of the machine cycle.
Other failures cannot be detected until a demand is
made on the safety-related function. An example of
such a safety-related function may be the use of an
electro-optical device protecting a hazard zone
where individuals do not normally enter the area
during a normal machine cycle.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
Machine control logic conforming to 8.10 can be
used to verify that a sensor or other device that
changes state at least once during a machine cycle
has done so. In the event that the device has not
changed state during the course of the cycle, the
resulting fault condition should be used to prevent
further cycling of the machine. See also, ANSI
B11.TR4.
When a failure is detected, the safety-related
function should meet the requirements below.
In the presence of a failure, the user shall be responsible to In the presence of a failure, it is recognized that
ensure that repetitive manual reset of the system or device is some control systems or devices can be manually
not used for production operation.
reset or can be reset by cycling the power to the
system or device off and on.
The intention of a manual reset is to encourage the
diagnosis of a failed component, subassembly,
device or module. A second failure may occur
during the diagnostic or troubleshooting process,
negating the safety-related function(s). Additional
safeguarding should be used to protect individuals
during this process.
Control reliability:
•
is one of the design strategies that may be
used to meet these requirements;
•
cannot prevent a repeat cycle in the event
of a major mechanical failure or in the
presence
of
multiple
simultaneous
component failures;
•
is not provided by simple redundancy.
There must be monitoring to assure that
redundancy is maintained.
For further information on safety-related functions,
see Annex B and ANSI B11.19.
9
Operation and maintenance
9.1
Training of personnel
E9.1 See also, Annex C.
9.1.1
Operating and maintenance personnel shall be
trained to perform the functions for which they are responsible.
The training shall include familiarizing personnel with the
portions of this standard related to their work. At a minimum,
training as appropriate shall include the following:
•
safe operation of the machine;
•
the functions and locations of manually operated
controls;
•
safe methods for installing, removing, and adjusting
tooling;
•
the location of all emergency stop devices;
•
the location and method for installation and
adjustment of all protective devices and guards, and
the use of safety procedures (e.g., fire prevention
equipment);
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
•
•
•
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
procedures for maintaining a safe work area;
inspecting and maintaining hydraulic piping systems;
lockout/tagout procedures.
9.1.2
Emphasis shall be placed on instructing personnel
concerning hazards involved in the following areas of machine
operation:
•
hazardous conditions associated with flying parts;
•
body parts in hazard zones;
•
pinch points involved with tool changing;
•
the restrictions on entering enclosures for electrical
and power transmission equipment.
E9.1.2 Personnel should be trained and instructed
in using the operations manual. Personnel should
read, or become familiar with, pertinent portions of
the manual.
9.1.3
The requirements for personal protective equipment
shall be determined by the user. Personnel shall be trained in
the proper use of this equipment, and the use of such
equipment shall be enforced.
9.2
Lockout/tagout/tryout
E9.2
A lockout/tagout/tryout procedure shall be established and See also, 29 CFR 1910.147 and 1910.333.
followed to limit exposure of personnel to unexpected machine
motion or energy release during servicing. See ANSI / ASSE
Z244.1.
9.3
Set-up
The user shall establish tool set-up procedures that will ensure Improperly mounted or adjusted guards or
compliance with clause 9.
improperly adjusted devices may instill a false sense
of security and create a severe hazard which the
operator does not recognize.
Manual machine drives are sometimes used for setup procedures.
9.3.1
Tool set-up procedures
To ensure that load–bearing tool components are suitable for
the task, procedures for tool selection, inspection, assembly,
and set–up shall be established.
E9.3.1
The equipment supplier's guidelines or the
recommendations of individuals knowledgeable with
roll-forming / roll-bending operations should be used
to establish these procedures.
9.3.2
Safeguarding during tool set-up
Where machine safeguarding means are removed, bypassed,
or defeated during tool set-up, alternate methods of
safeguarding shall be utilized.
Any machine safeguarding means which was removed, bypassed, or defeated during tool set-up shall be re-established
before returning the machine to normal operation.
9.4
Operation
9.4.1
Operating procedures
9.4.1.1
Operating procedures shall be established, E9.4.1.1 The documentation should include but not
documented, and supervised to ensure that these procedures be limited to:
are being followed. Refer to clause 5 for hazard identification.
•
A description of the assigned task;
•
The function of controls to be utilized in
performing the assigned task;
•
The hazards associated with the assigned
task;
•
The designated method of safeguarding;
•
The methods of function-testing or otherwise
ensuring the proper function of safeguarding
means.
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AMERICAN NATIONAL STANDARD
STANDARD REQUIREMENTS
9.4.1.2 A formal risk assessment/risk reduction process shall
be used to reduce exposure to hazard(s) by identifying
appropriate administrative procedures or other protective
measures where the use of guards and protective devices is
not practicable.
B11.12–2005 (R2020)
EXPLANATORY INFORMATION
E9.4.1.2 The user should ensure that the operator is
properly trained in the use of the procedure and
aware of the hazards involved. For more information
on hazard reduction, see ANSI B11.TR3.
9.4.2
Machine initiation
The initiation of the automatic, semi–automatic, or manual
modes by the operator shall only be allowed when all of the
following conditions are satisfied:
•
the associated safeguards are in place and functioning;
•
no persons are present within the hazard zone(s); and
•
operating procedures have been followed.
9.5
Maintenance
9.5.1
Maintenance and set-up
The user shall ensure that maintenance instructions,
procedures and recommendations for the operation and
maintenance of the machine are established, provided and
used.
E9.5.1
The user should utilize the supplier’s instructions
and recommendations to establish maintenance
instructions and procedures for the operation and
maintenance of the machine.
9.5.2
Lockout/tagout/tryout
E9.5.2
A lockout/tagout/tryout procedure shall be established and See also, 29 CFR 1910.147 and 1910.333.
followed so as to limit exposure of personnel to unexpected
machine motion during maintenance and repair. See ANSI /
ASSE Z244.1.
9.5.3
Inspection and maintenance
Procedures shall be developed to ensure that the machine is
inspected periodically and maintained as required to ensure
non–hazardous operation.
E9.5.3
The frequency of maintenance and inspections is
dependent on the use of the machine. The user
should consider the supplier's recommendations
when determining the period between inspections.
When the machine or its associated equipment is
modified, the user should ensure that maintenance
instructions and procedures are updated and that
maintenance personnel are trained in the revised
procedures.
9.5.4
Repairs
The user shall ensure that all necessary repairs are completed
prior to returning the machine and its associated equipment to
operation.
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AMERICAN NATIONAL STANDARD
B11.12–2005
Annex A (informative) – Examples of roll-forming and roll-bending machines
Figure 1 – Example of a roll-forming machine
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AMERICAN NATIONAL STANDARD
B11.12–2005
Figure 2 – Examples of roll-forming
Figure 3 – Example of a roll-bending machine
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AMERICAN NATIONAL STANDARD
B11.12–2005
Figure 4 – Examples of roll–bending
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Figure 5 – Example of a run button
Figure 6 – Some examples of foot controls
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Hazard Line
Figure 7 - Positioning of Guards
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Figure 8 – Two–hand control device (for roll–bending machines only)
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AMERICAN NATIONAL STANDARD
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Annex B (Informative) – Performance of the safety-related function(s)
The purpose of the requirements of this standard is to prevent exposure to hazardous motion (or situations). The
level of performance of the safety-related function(s) depends on the level of risk associated with the hazard (see
clause 5).
There are various design strategies that may be used to ensure that failures of components, modules, devices or
systems meet the level of performance required above. Some design strategies may allow an accumulation of single
failures and yet still stop (or prevent the re-initiation of) hazardous motion (or situations) when the next critical failure
would cause loss of the safety-related function. Other strategies include self-diagnosis to determine and respond to
failures. Still other strategies use tried and proven components and design principles to reduce the probability of a
failure to a tolerable risk. Control reliability is a design strategy, method or feature that separates the safety-related
functions of a system into components, modules, devices or systems that can be monitored or checked by other
components, modules, devices or systems. It is axiomatic that protection from the loss of safety-related functions
due to multiple, simultaneous independent failures of components, sometimes referred to as “fail-safe”, is not
practically achievable. Catastrophic failure of the machine actuator (electrical, mechanical or fluidic) may result in the
loss of the safety-related function. The use of redundant components, modules, devices or systems (with or without
monitoring or checking) is frequently used in process control systems where the goal is to maintain the process in the
event of a failure. Aircraft systems, chemical processing plants and electrical power transmission systems are
examples of applications where the process must continue in the presence of a failure. Control reliability is not
provided by simple redundancy. There must be monitoring to assure that redundancy is maintained. Control
reliability uses monitoring and checking to determine that a discernable component, module, device or system has
failed and that the hazardous motion (or situation) is stopped, or prevented from starting or restarting. Control
reliability ensures that a failure of the control system or device will not result in the loss of the safety-related
function(s).
NOTE - Because some failures cannot be detected until the completion of a cycle or a portion of the cycle, loss of
safety-related functions may occur for a portion of the cycle.
Control reliability of electrical, electronic, pneumatic, or hydraulic systems or devices frequently consists of monitored,
multiple and independent parallel or series components, modules, devices or systems. Control reliability of machine
control systems or devices can be achieved by the use of, but not limited to, one or both of the following:
•
The use of two or more dissimilar components, modules, devices or systems, with the proper operation of
each being verified (monitored) by the other(s) to ensure the performance of the safety function(s).
•
The use of two or more identical components, modules, devices or systems, with the proper operation of
each being verified (monitored) by the other(s) to ensure the performance of the safety function(s).
These methods require that the safeguarding device, its interface to the control system (or directly to the actuator
control) and actuator control meet the above requirements.
Another control reliability strategy may be used when the machine motion is stopped and reinitiated at least once per
cycle. This strategy requires that the control system and the actuator control utilize the design methods above. The
safeguarding device and its interface may or may not be control reliable. To ensure that these elements cannot
cause a loss of the safety-related function(s), the control system must be designed to require that the device and its
interface are exercised automatically or by the operator (e.g., releasing hand controls or interrupting an electro-optical
device) before a subsequent machine cycle may be initiated.
NOTE – The requirements of control reliability are not comparable to the requirements of ISO 13849-1, and exceed
the requirements of category 2.
The achievement of control reliability is dependent upon the selection and integration of components, modules,
devices and systems that have been specifically designed and intended for use in safety-related functions. A
disciplined design process, including design guidelines, peer review and other elements, is important for achieving
completeness and accuracy of the design, and should be implemented to ensure that control reliability is achieved.
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AMERICAN NATIONAL STANDARD
B11.12–2005
Annex C (informative) – Guidelines for general training of operators of rollforming and roll-bending machines
In order to establish training guidelines, it is important to understand the nature of the industry and its practices.
Some significant points include:
• There is usually only one operator assigned to each machine with rarely more than two operators per
machine.
• It is common for a user to have only one or two machines of this type in a plant. The largest of plants may
have ten or more machines.
• On multi-machine user operations where the machines are run in an automatic mode, these systems may
have one operator to support two or more units as required.
• The operators of these machines can usually be classified as skilled, particularly since the operators
frequently perform their own set-up work.
• There are no trade schools or formal established training programs for operators.
In consideration of these characteristics, the following guidelines are recommended to help ensure safe operation of
roll-formers and roll-benders.
• Each user should have job descriptions that outline the skills required for each operator position. The job
descriptions should include what is expected of each operator as covered by clause 9 of this standard.
• The training of operators should be of the "On-The-Job" type. Trainees should be initially assigned to work
with experienced personnel or under the direct supervision of a knowledgeable individual until the trainee has
gained sufficient familiarity to work independently.
• A training schedule should be established by each user. This schedule should outline the progression of
advancement through the necessary trainee and operator positions as covered by the job descriptions. A
training timetable can be a part of this training schedule, but the emphasis should be on actual skills acquired
rather than the elapsed time in an individual's training history.
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AMERICAN NATIONAL STANDARD
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Annex D (Informative) – Audit List
The purpose of this listing is to aid in the evaluation of meeting the requirements of this standard. Anyone
performing this audit should have a good understanding of the requirements of this standard and of the
requirements of ANSI B11.19 - Performance Criteria for Safeguarding. The items in this audit list may only
apply to the supplier or only to the user, or both.
I.
Responsibilities
Do personnel managing and operating the roll-forming / roll-bending system have an understanding of who
is responsible for safety on the equipment?
Refer to clause 4 and Introduction.
Yes___ No___ NA___
II.
Hazard control (Clause 5)
Have task-based hazards associated with roll-forming and roll-bending operation and maintenance been
identified?
Sub clause 5.1
Yes___ No___ NA___
Has a documented risk assessment been completed and a risk reduction plan been implemented?
Sub clause 5.2
Yes___ No___ NA___
III.
Design and construction (Clause 6)
.
1. Do components selected have specification limits established by their manufacturer, and equal to
or greater than any adjustment setting of the system?
Sub clause 6.2
Yes___ No___ NA___
2. Do electrical, mechanical, hydraulic, pneumatic (or some combination) control systems have separate
manual action to restart the machine?
Sub clause 6.3
Yes___ No___ NA___
3. Is initiation of roll-former or roll-bender motion prevented when a new operating mode is selected?
Sub clause 6.4
Yes___ No___ NA___
4. Is safeguarding activated prior to automatic, semi-automatic and manual mode motion?
Sub clause 6.4
Yes___ No___ NA___
5. Are sensing device voltages equal to or less than 24 volts when the workpiece is a conductor?
Sub clause 6.4.1
Yes___ No___ NA___
6. Does electrical equipment meet the requirements of ANSI/NFPA 70 and ANSI/NFPA 79?
Sub clause 6.5
Yes___ No___ NA___
7. Are operator control circuits of 120 volts ac or less from a transformer with an isolated secondary?
Sub clause 6.6.1
Yes___ No___ NA___
8. Are operator control mechanisms isolated from voltages exceeding 120 volts ac?
Sub clause 6.6.1
Yes___ No___ NA___
9. Is the control system protected against false operation due to grounding or improper shielding?
Sub clause 6.6.2
Yes___ No___ NA___
10. Are all hydraulic components rated for the maximum hydraulic pressure in the respective system?
Sub clause 6.7.6
Yes___ No___ NA___
11. Is a data plate prominently and legibly displayed on the roll-former or roll-bender that shows the
maximum gauge, horsepower or tonnage?
Sub clause 6.7.6
Yes___ No___ NA___
12. Does the hydraulic system have means to maintain the fluid quality to prevent a hazardous malfunction
of the roll-former or roll-bender including filtration and temperature control?
Sub clause 6.7.3
Yes___ No___ NA___
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13. Are the hydraulic components compatible with the hydraulic fluid?
Sub clause 6.7.4
Yes___ No___ NA___
14. Do hydraulic accumulators meet the ANSI / ASME Pressure Vessel Code?
Sub clause 6.7.5
Yes___ No___ NA___
15. Do hydraulic systems with accumulators have a means to isolate or vent the pressure to prevent
unintended equipment motion?
Sub clause 6.7.2
Yes___ No___ NA___
16. Are accumulators charged with the proper gas for the particular hydraulic fluid?
Sub clause 6.7.4
Yes___ No___ NA___
17. Are pneumatic components rated for the maximum system pressures?
Sub clause 6.7.6
Yes___ No___ NA___
18. Is compressed air supply conditioned to meet the equipment supplier’s requirements?
Sub clause 6.7.6
Yes___ No___ NA___
19. Do motor starters disconnect the motors from power in the event of control voltage or power-source
failure and require actuation of a motor start button to restart?
Sub clause 6.8
Yes___ No___ NA___
20. Will fluctuations or interruptions of power immediately initiate stopping action of hazardous movements
without causing other hazardous situations?
Sub clause 6.8
Yes___ No___ NA___
21. Is manual restarting required after power has been restored to the roll-former or roll-bender?
Sub clause 6.8
Yes___ No___ NA___
22. Is a means provided for the isolation, containment or controlled release of stored energy?
Sub clause 6.9
Yes___ No___ NA___
23. Are all power sources capable of being locked out for servicing needs?
Sub clause 6.9
Yes___ No___ NA___
24. Are hazardous conditions related to stored energy prevented when there is a loss of power?
Sub clause 6.10
Yes___ No___ NA___
25. Is the roll-former or roll-bender control or power system designed so that external interferences do not
adversely affect the safe operation of the roll-former or roll-bender?
Sub clause 6.11
Yes___ No___ NA___
26. Do safety-related functions in the control system meet the requirements of
Sub clause 6.12?
Yes___No___ NA___
27. Is the machine initiation control station(s) located outside the associated hazard zone(s)?
Sub clause 6.13
Yes___No___ NA___
.
28. Is “cycle start” control arranged so that the roll-forming / roll-bending machine cannot be accidentally
started?
Sub clause 6.14
Yes___ No___ NA___
29. Does the roll-former or roll-bender have a Category “0” stop control?
Sub clauses 6.14
Yes___ No___ NA___
30. Does each activated device have to be individually reset following the restoration of power after an
“emergency stop”?
Sub clause 6.14
Yes___ No___ NA___
31. Does the roll-former or roll-bender have an emergency stop as referenced in 6.14.2?
Sub clause 6.14
Yes___ No___ NA___
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32. Are there additional “emergency stop” devices in easily accessible non-hazardous locations?
Sub clause 6.14
Yes___ No___ NA___
33. If a cable is used as an “emergency stop” device, does the breaking of the cable initiate the emergency
stop command?
Sub clause 6.14.5
Yes___ No___ NA___
34. Does each roll-former or roll-bender control station have a large red mushroom head “emergency stop”
clearly identified self latching pushbutton with a yellow background that upon momentary contact removes
power from the roll-former or roll-bender actuators and motors?
Sub clauses 6.14
Yes___ No___ NA___
35. Are operator stations outside hazard areas and are they readily accessible?
Sub clause 6.15
Yes___ No___ NA___
36. If more than one operator station is provided, can only one be used at a time?
Sub clause 6.15
Yes___ No___ NA___
37. Does switching from one operator station to the other create a hazard?
Sub clause 6.15
IV.
Yes___ No___ NA___
Installation, testing and start-up (Clause 7)
38. Is the roll-former or roll-bender foundation capable of bearing the normal static and dynamic loads?
Sub clause 7.2
Yes___ No___ NA___
39. Is the proper amount of light provided to ensure that personnel can safely perform their tasks?
Sub clause 7.3
Yes___ No___ NA___
40. Is fire protection equipment provided where non fire-resistant hydraulic fluids are used?
Sub clause 7.4
Yes___ No___ NA___
41. Was a safety review of work to be done made with personnel involved in start-up and testing of the rollformer or roll-bender prior to the start-up process?
Sub clause 7.5.1
Yes___ No___ NA___
42. Are only assigned personnel permitted to operate the roll-former or roll-bender during testing and startup?
Sub clause 7.5.2
Yes___ No___ NA___
43. Is a safeguarding means provided for personnel during testing and start-up?
Sub clause 7.5.3
Yes___ No___ NA___
V.
Safeguarding
(Clause 8)
44. Do guards prevent the entry of the body or body parts into the hazard area by reaching over, under,
around, or through the guard?
Sub clause 8.2
Yes___ No___ NA___
45. Are guards installed such that they do not create pinch points between themselves and moving
components?
Sub clause 8.2
Yes___ No___ NA___
46. Are guards secured such that they cannot be easily removed or are interlocked with the roll-former or
roll-bender control circuit to prevent movement if the guards are removed?
Sub clause 8.2
Yes___ No___ NA___
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47. Are safeguarding devices interlocked with the control circuit either to prevent movement or to limit
movement of the roll-former or roll-bender components if any part of a person’s body is within a potential
hazard area?
Sub clause 8.3
Yes___ No___ NA___
48. Are the safeguarding devices designed such that they do not present a hazard?
Sub clause 8.3
Yes___ No___ NA___
49. Is the safeguarding circuit designed so that the device cannot initiate a cycle starting control?
Sub clause 8.3
Yes___ No___ NA___
50. Does the safeguarding device prevent the component it is controlling from moving in an unsafe direction
if the hydraulic pump fails?
Sub clause 8.3
Yes___ No___ NA___
51. Is the safeguarding device unaffected by ambient factors such as light, temperature, and electrical
noise?
Sub clause 8.3
Yes___ No___ NA___
52. Are safeguarding devices mounted such that roll-former or roll-bender component movement or the
normal movement, of personnel working in the area, do not affect them?
Sub clause 8.3
Yes___ No___ NA___
53. Are safeguarding devices prevented from affecting other electronic devices?
Sub clause 8.3
Yes___ No___ NA___
54. Do awareness devices, where used to alert personnel of an approaching or present hazard, emit an
audible or visual signal distinguishable from other signals in the area?
Sub clause 8.4
Yes___ No___ NA___
55. Are safeguarding methods used and, if so, are personnel aware of their proper use?
Sub clause 8.5
Yes___ No___ NA___
56. If safe work procedures are applied, is there a system to ensure their use?
Sub clause 8.6
Yes___ No___ NA___
57. Do shields comply with the requirements of sub clause 8.2?
Sub clause 8.7
Yes___ No___ NA___
58. Do all safety-related functions comply with the requirements of sub clause 8.10?
Yes___ No___ NA___
VI.
Operation and maintenance (Clause 9)
59. Are operators and maintenance personnel trained to perform the functions for which they are
responsible, including (at a minimum) the following?
– Functions and location of manually operated controls;
– Safe methods for installing, removing and adjusting tooling;
– Location of all emergency stop devices;
– Location and method for installation and adjustment of all protective devices and guards;
– Use of safety procedures;
– Procedures for maintaining a safe work area;
– Inspecting and maintaining hydraulic piping systems;
– Lockout/tag out/tryout procedures.
Sub clause 9.1.1
Yes___ No___ NA___
60. Are personnel trained in the following?
– Hazard conditions associated with flying parts;
– Body parts in hazard areas;
– Pinch points involved with tool changing;
– Restrictions on entering enclosures for electrical and power transmission equipment.
Sub clause 9.1.2
Yes___ No___ NA___
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61. Have the following personal protective equipment requirements been met?
– Personal protective equipment identified.
– Personnel trained in the use of equipment.
– Personal protective equipment use enforced.
Sub clause 9.1.3
Yes___ No___ NA___
62. Has a lockout/tagout/tryout procedure been established and followed?
Sub clause 9.2
Yes___ No___ NA___
63. Have procedures been established for load bearing tool selection, inspection, assembly, and set-up?
Sub clause 9.3.1
Yes___ No___ NA___
64. Where safeguarding means are removed, bypassed, or defeated during tool set-up, have alternate
safeguarding means been established?
Sub clause 9.3.2
Yes___ No___ NA___
65. Is there an alignment procedure for tooling including the die, die stem, extrusion stem, billet container,
billet loader, dummy block handler, and mandrel to prevent interference between these components?
Sub clause 9.3.3
Yes___ No___ NA___
66. Are operating procedures established, documented and supervised for compliance?
Sub clause 9.4.1.1
Yes___ No___ NA___
67. Is viewing the exit hole of the platen permitted only by indirect means?
Sub clause 9.4.1.2
Yes___ No___ NA___
68. Are administrative controls or other protective measures used to reduce exposure to hazard(s) where
safeguarding means are not practicable?
Sub clause 9.4.1.3
Yes___ No___ NA___
69. Are necessary devices provided so that operators do not have to reach into hazard areas to lubricate or
degrease the tools while the roll-forming / roll-bending machine is in its normal operating mode?
Sub clause 9.4.2
Yes___ No___ NA___
70. Is the initiation of the automatic, semi-automatic or manual mode of operation permissible only if the
following conditions are satisfied?
– Safeguards are in place and functioning;
– No person is present within the hazard area(s);
– Operating procedures have been followed.
Sub clause 9.4.3
Yes___ No___ NA___
71. Are maintenance procedures established and documented for the roll-former or roll-bender in order to
maintain it in non-hazardous working condition?
Sub clause 9.5
Yes___ No___ NA___
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