Many hazards are associated with metal fabrication. Machine guarding and safe work practices must be implemented to protect employees from hazards associated with this type of work.
Hazard associated with Metal Fabrication Equipment include:
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Point of operations hazards the point where work is performed on the material, such as cutting, shearing, shaping, boring, or forming stock.
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Power transmission apparatus All components of the mechanical system which transmits energy to components. Types of energy transmission include flywheels, pulleys, belts, connecting rods, couplings, cams, spindles, chains, cranks, and gears.
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Other moving parts - All parts of the machine which move while the machine is working. These can include reciprocating, rotating, and transverse moving parts, as well as feed mechanisms and auxiliary parts of the machine.
Methods of guarding these hazards include guards, devices, location or distance, feeding devices and/or miscellaneous aids.
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Guards can be fixed, interlocked, adjustable, or self-adjusting. Fixed guards provide a barrier and are a permanent part of the machine. Fixed guards are the best method of guarding.
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Devices include presence sensing, pullbacks, restraints, safety controls, or gates.
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Hazards can also be guarded by location or distance . The OSHA 0-10 table in 29 CFR
1910.217 shows the distances that guards should be positioned from the danger line in accordance with the required openings.
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Feeding devices can be automatic and semiautomatic feeding or ejecting and robots.
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Miscellaneous Aids such as awareness barriers, protective shields, or hand feeding tools can also be used. Hand feeding tools can only be used with one of the techniques listed above.
Equipment used in Metal Fabrication can include but is not limited to power presses, lathes, milling machines, drill presses, pneumatic/hydraulic press brakes and various saws. All equipment used for metal fabrication must be properly guarded in accordance with the specific requirements of Subpart O
(Machinery and Machine Guarding).
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Power Presses : Power presses are used to work on metal or other material with cutting, shaping, or combination dies attached to plungers, platens, or slides (rams). Power presses are used in a wide variety of industries to punch, shear, and form metal and other materials. Power presses include mechanical, hydraulic, pneumatic, hydra-mechanical, mechanical-friction clutch and powered press brakes. General machine guards such as barrier guards, two-hand tripping devices and electronic safety devices must be provided to protect the operator and other employees in the machine area from hazards created by point of operation, nip points etc.
Specific requirements for Mechanical Power Presses are covered in 29 CFR 1910.217.
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Lathes : The primary hazards of lathes are contact with rotating parts and contact at the point of operation. Operators' hands, clothing, or jewelry may be caught on the rotating parts and pulled into the machine. The rotating chuck or drilling bit should be guarded and safety glasses should be worn to protect from flying particles.

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Drill Presses/Milling Machines : The rotating chuck and drill must be guarded on drill presses and milling machines. Safety glasses must also be worn to protect employees from flying particles.
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Pneumatic/Hydraulic Press Brakes : Four types of press brakes include part revolution, hydraulic, hydra-mechanical and mechanical-friction clutch. They are mechanically or hydraulically powered and are primarily used for bending and forming sheet metal. Although most press brake operations do not require the operators to place their hands or any part of their body into the point of operation, exposure to point of operation injuries still exists. Operating controls, especially foot pedals, introduce the possibility of accidental cycling. Press brakes can be guarded using presence sensing devices, two-hand control devices, pull back devices or restraint devices.
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Saws : There are several types of portable and stationary power saws. Accidents may occur if the operator is inexperienced, improperly trained or if the blade is not properly guarded. Avoid loose-fitting clothes and long hair that might become entangled in a power tool and remove rings, watches, neck chains and other jewelry. Safety glasses should be worn to protect from flying particles.
Additional Safety Tips :
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While performing maintenance on equipment, always follow the requirements set forth in the control of hazardous energy (Lockout/Tagout) 1910.147.
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Ensure employees are wearing the required personal protective equipment (PPE) for the job task they are performing. This can include but is not limited to safety glasses for flying particles, cut resistant gloves for lacerations to the hands and arms, hard hats for overhead hazards and steel toed shoes.
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Perform preventative maintenance on your equipment to prevent unexpected malfunction during use.
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Keep the work area clean to prevent slipping or falling hazards.
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Be aware that material handling is hazardous as material may have sharp edges and be slippery or heavy.
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Train all employees on safe work procedures and equipment operation.
Resources: http://www.osha.gov/SLTC/etools/machineguarding/index.html
(Machine Guarding E-Tool) http://www.oshainfo.gatech.edu/techguides.html
(Georgia Tech OSHA Safety and Health Consultation
Program’s Tech Guides) http://www.osha.gov/pls/oshaweb/owastand.display_standard_group?p_toc_level=1&p_part_number=19
10&v_description=General+Industry+-+%28Standards+-+29+CFR%29 (OSHA’s General Industry
Standards)