Loading (50 kb)...'
(continued)
The test specification and procedure shall be submitted to the validation organization for review and validation prior to the test. The validation organization representative shall witness at least one set of tests.
4. Compliance with sections 4208.1(e)(3) and (i)(6). Each reaction time required to calculate the Safety Distance, including the brake monitor setting, shall be documented in separate reaction time tests. These tests shall specify the acceptable tolerance band sufficient to assure that tolerance build-up will not render the safety distance unsafe.
a. Integrated test of the press fully equipped to operate in the PSDI mode shall be conducted to establish the total system reaction time.
b. Brakes which are the adjustable type shall be adjusted properly before the test.
5. Compliance with section 4208.1(b)(3).
a. Prior to conducting the brake system test required by section 4208.1(b)(2), a visual check shall be made of the springs. The visual check shall include a determination that the spring housing or rod does not show damage sufficient to degrade the structural integrity of the unit and the spring does not show any tendency to interleave.
b. Any detected broken or unserviceable springs shall be replaced before the test is conducted. The test shall be considered successful if the stopping time remains within that which is determined by section 4208.1(i)(6), for the safety distance setting. If the increase in press stopping time exceeds the brake monitor setting limit defined in section 4208.1(e)(3), the test shall be considered unsuccessful and the cause of the excessive stopping time shall be investigated. It shall be ascertained that the springs have not been broken and that they are functioning properly.
6. Compliance with section 4208.1(g).
a. Tests which are conducted by the manufacturers of electrical components to establish stress, life, temperature and loading limits must be tests which are in compliance with the provisions of the National Electrical Code.
b. Electrical and/or electronic cards or boards assembled with discreet components shall be considered a subsystem and shall require separate testing that the subsystems do not degrade in any of the following conditions:
(1) Ambient temperature variation from 20 ° C to -50 ° C.
(2) Ambient relative humidity of 99 percent.
(3) Vibration of 45G for one millisecond per stroke when the item is to be mounted on the press frame.
(4) Electromagnetic interference at the same wavelengths used for the radiation sensing field, at the power line frequency fundamental and harmonics, and also from autogenous radiation due to system switching.
(5) Electrical power supply variations of -15 percent.
c. The manufacturer shall specify the test requirements and procedures from existing consensus tests in compliance with the provisions of the National Electrical Code.
d. Tests designed by the manufacturer shall be made available upon request to the validation organization. The validation organization representative shall witness at least one set of each of these tests.
7. Compliance with section 4208.1(i)(5).
a. The manufacturer shall design a test to demonstrate that the prescribed minimum object sensitivity of the presence sensing device is met.
b. The test specifications and procedures shall be made available upon request to the validation organization.
8. Compliance with section 4208.1(i)(11).
a. The manufacturer shall design a test(s) to establish the hand tool extension diameters allowed for variations in minimum object sensitivity response.
b. The test(s) shall document the range of object diameter sizes which will produce both single and double break conditions.
c. The test(s) specifications and procedures shall be made available upon request to the validation organization.
9. Integrated Tests Certification/Validation.
a. The manufacturer shall design a set of integrated tests to demonstrate compliance with the following requirements:
Sections 4208.1 f(2), (3), (4), (5), (6), (7), (8), (9), (11), (12), (13), (14) and (16).
b. The integrated test specifications and procedures shall be made available to the validation organization.
10. Analysis.
a. The manufacturer shall submit to the validation organization the technical analysis such as Hazard Analysis, Failure Mode and Effect Analysis, Stress Analysis, Component and Material Selection Analysis, Fluid Compatibility, and/or other analyses which may be necessary to demonstrate compliance with the following requirements:
Sections 4201.8 (b)(1), (3),; (c)(1)(A), (c)(1)(C), (c)(2); (e)(1), (2), (3); (f)(1), (3), (4), (6), (7), (8), (9), (10), (11), (12), (13), (14), (15), (16); (g); (h)(1), (2); (i)(5), (6), (9), (10), (11); (j)(1) and (2).
11. Types of tests Acceptable for Certification/Validation.
a. Test results obtained from development testing may be used to certify/validate the design.
b. The test results shall provide the engineering data necessary to establish confidence that the hardware and software will meet specifications; the manufacturing process has adequate quality control; and the data acquired was used to establish processes, procedures, and test levels supporting subsequent hardware design, production, installation and maintenance.
12. Validation for Design Certification/Validation.
If, after review of all documentation, tests, analyses, manufacturer's certifications, and any additional tests which the third-party validation organization believes are necessary , the third-party validation organization determines that the PSDI safety system is in full compliance with the applicable requirements of sections 4192 through 4211 and this Appendix A, it shall validate the manufacturer's certification that it so meets the stated requirements.
C. Installation Certification/Validation Requirements
1. The employer shall evaluate and test the PSDI system installation, shall submit to the Division-recognized third-party validation organization the necessary supporting documentation, and shall certify that the applicable requirements of sections 4192 through 4211 and this Appendix A have been met and that the installation is proper.
2. The Division-recognized third-party validation organization shall conduct tests, and/or review and evaluate the employer's installation tests, documentation and representations. If it so determines, it shall validate the employer's certification that the PSDI safety system is in full conformance with all applicable requirements of sections 4192 through 4211 and this Appendix A.
D. Recertification/Revalidation Requirements
1. A PSDI safety system which has received installation certification/validation shall undergo recertification/revalidation the earlier of:
a. Each time the systems hardware is significantly changed, modified, or refurbished;
b. Each time the operational conditions are significantly changed (including environmental, application or facility changes, but excluding such changes as die changes or press relocations not involving revision to the safety system);
c. When a failure of a significant component has occurred or a change has been made which may affect safety; or
d. When one year has elapsed since the installation certification/validation or the last recertification/revalidation.
2. Conduct of recertification/revalidation. The employer shall evaluate and test the PSDI safety system installation, shall submit to the Division-recognized third-party validation organization the necessary supporting documentation, and shall recertify that the applicable requirements of sections 4192 through 4211 and this Appendix are being met. The documentation shall include, but not be limited to, the following items:
a. Demonstration of a thorough inspection of the entire press and PSDI safety system to ascertain that the installation, components and safeguarding have not been changed, modified or tampered with since the installation certification/validation or last recertification/revalidation was made.
b. Demonstrations that such adjustments as may be needed (such as to the brake monitor setting) have been accomplished with proper changes made in the records and on such notices as are located on the press and safety system.
c. Demonstration that review has been made of the reports covering the design certification/validation, the installation certification/validation, and all recertification/revalidations in order to detect any degradation to an unsafe condition, and that necessary changes have been made to restore the safety system to previous certification/validation levels.
3. The Division-recognized third-party validation organization shall conduct tests, and/or review and evaluate the employer's installation, tests, documentation and representations. If it so determines, it shall revalidate the employer's recertification that the PSDI system is in full conformance with all requirements of sections 4192 through 4211 and this Appendix A.
s 4209. Additional Requirements for Safeguarding Presses with Part Revolution Clutches.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4210. Hand-Operated Levers.
(a) Hand-lever-actuated power operated presses shall be equipped with a spring latch on the operating lever to prevent premature or accidental tripping.
(b) The operating levers on hand-tripped presses having more than one operating station shall be interlocked to prevent the tripping of the power operated press except by the concurrent use of all levers.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4211. Two-Hand Trip.
(a) A two-hand trip shall have the individual operator's hand controls protected against unintentional operation and have the individual operator's hand controls arranged by design and construction and/or separation to require the use of both hands to trip the press and use a control arrangement requiring concurrent operation of the individual operator's hand controls.
(b) Two-hand trip systems on full revolution clutch machines shall incorporate an antirepeat feature.
(c) If two-hand trip systems are used on multiple operator presses, each operator shall have a separate set of controls.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4212. Control Reliability.
Note: Authority cited: Sections 142 and 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4213. Special Purpose Press Drive Motor Interlocks.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4214. Press Brakes Mechanically or Hydraulically Powered.
(a) Press brakes, mechanically or hydraulically powered, shall be guarded in a manner that will accomplish the following:
(1) Restrain the operator(s) from inadvertently reaching into the point of operation, or
(2) Inhibit machine operation if the operator's hand or hands are inadvertently within or placed within the point of operation, or
(3) Automatically withdraw the operator's hands if they are inadvertently within the point of operation.
(b) Devices that will accomplish (a)(1), (2) and (3) above include but are not restricted to those listed below:
(1) Presence-sensing device.
(2) Holdout or Restraint Device.
(3) Pullout Device.
(4) Two-Hand Control Device (see 4193(e)).
(5) Type A or B Gate or Movable Barrier Device.
(6) Fixed Barrier Guard (see 4207).
(7) An arrangement of stops and holding devices such as a feed table or other material support, which will assist in positioning and supporting the material being worked so that the controls can be remotely located. When such stops and material supports are used, the controls shall be so located that the operator(s) can not activate the control(s) and reach into the point of operation.
(8) Any other system of guards, automatic or semi-automatic feeds, etc., that will allow the material to be worked and effectively prevent the operator's hand(s) from entering or being in the point of operation during the die-closing portion of the press stroke.
(9) When the nature of the work or size and/or shape of material being worked is such that compliance with the provisions of Section 4214(b)(1) through (8) is not practical, the employer shall ensure compliance with the following:
(A) The operator shall be qualified, and
(B) The operator maintains a safe distance from the point of operation through the use of hand tools or the size and/or shape of the material being worked so that the operator's hands never enter the point of operation, and
(C) Only general-purpose press brakes with general-purpose dies are used.
(c) Inching.
(1) Two-hand inching devices shall be used on special-purpose presses for set-up work and adjustment of the press. [See 4193(d)].
(2) General-purpose presses shall be inched for set-up work and adjustment by a single control protected against accidental actuation so that the worker can not reach into the point of operation while inching the press.
(d) Control Reliability [see 4204(a) and (b)].
(e) Point of operation guards and devices shall comply with Sections 4207 and 4208 respectively.
(f) Slide counter-balance systems shall comply with Section 4194.
(g) Air controlling equipment shall comply with Section 4195.
(h) Hydraulic Equipment. The maximum designed working pressures in any hydraulic system on a press-brake shall not exceed the safe working pressure rating of any component used in that system.
(i) Brakes. Friction brakes for stopping or holding a slide movement shall comply with Section 4200(a).
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4215. Hydraulic Power Presses (Punch Presses).
(a) Hydraulic power presses shall be guarded in a manner that will accomplish the following:
(1) Restrain the operator(s) from inadvertently reaching into the point of operation, or
(2) Inhibit machine operation if the operator's hand or hands are inadvertently within the presence sensing field or inadvertently within or placed within the point of operation, or
(3) Automatically withdraw the operator's hands if they are inadvertently within the point of operation.
(b) Devices that will accomplish (a)(1), (2) or (3) above include, but are not restricted to those listed below:
(1) Presence-sensing devices
(2) Holdout or restraint devices
(3) Pullout devices
(4) Two-hand control devices [see 4193(e)]
(5) Gate or movable barrier devices
(6) Fixed barrier guard (see 4207).
(7) Any other system of guards, automatic or semi-automatic feeds, etc., that will allow the material to be worked and effectively prevent the operator's hand(s) from entering or being in the point of operation during the die-closing portion of the press stroke.
(c) Inch. Inching controls shall comply with Section 4193(d).
(d) Point of operation guards and devices shall comply with Sections 4207 and 4208 respectively.
(e) Hydraulic Equipment. The maximum design working pressures in any hydraulic system on a hydraulic powered press shall not exceed the safe working pressure rating of any component used in that system.
(f) Press Control Systems.
(1) Stop Control. At least one of the following shall be provided as a means of stopping press motion:
(A) Stop. A means of stopping all press motion. Actuation of the stop control shall immediately deactivate all press controls. The stop control shall override any other control.
(B) If a stop button is provided, it shall stop the press slide(s) and/or return the slide(s) to the initial starting position.
(2) Mode Selector. When more than one mode is furnished, a means of selecting the different modes such as Off, Inch, Single Cycle, and Automatic shall be supplied with the press control. Selection shall be by means capable of being supervised by the employer. It is not intended that all these press modes be required or be limited to the above.
(A) Off. The off mode shall make the press control inoperative.
(B) Inch. Press controls which provide this mode shall require the following conditions:
(i) The slide will have motion only during the time of operation of the actuating control(s) used for this mode.
(ii) The inching control cannot set up an unintended movement by contacting or overriding the stroke limiting mechanisms.
(C) Single Cycle. Press controls which have this mode shall require that:
(i) Actuation of the operating controls shall initiate the cycle.
(ii) Re-actuation of operating controls is required to initiate a new cycle.
(iii) The control system shall be designed to require an intended action of the operator before an interrupted cycle can be resumed.
(D) Automatic. Press controls which contain the automatic mode shall be designed so that the initiation of automatic run shall require an action by the operator in addition to the selection of automatic on the mode selector by the supervisor, before actuation of the operating means will result in automatic cycling. An interrupted automatic cycle must be initiated as specified in this paragraph.
(3) Actuating Control Selection. If more than one actuating means is provided, the selection method shall be designed so that the selection is controlled by the employer.
(4) Press Control Reliability. When required by Section 4193(m) the press control shall be designed to prevent initiation of a successive stroke signal in the event that a failure occurs within the press control.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4216. Rivet Setting Equipment.
(a) Rivet Setting Equipment shall be guarded in a manner that will accomplish the following:
(1) Restrain the operator(s) from inadvertently reaching into the point of operation, or
(2) Inhibit machine operation if the operator's hand or hands are inadvertently within or placed within the point of operation, or
(3) Automatically withdraw the operator's hands if they are inadvertently within the point of operation.
(b) Devices or guards that will accomplish (a)(1), (2) or (3) above include, but are not restricted to those listed below:
(1) Presence-sensing device
(2) Holdout or restraint devices
(3) Pullout devices
(4) Two-hand control devices (see 4211)
(5) Type A gate or movable barrier devices
(6) Fixed barrier guard (see 4207)
(7) Any other system of guards, automatic or semi-automatic feeds, etc., that will allow the material to be worked and effectively prevent the operator's hand(s) from entering or being in the point of operation during the die-closing portion of the press stroke.
(8) When the nature of the work or size and/or shape of material being worked is such that compliance with the provisions of Section 4216(b)(1) through (7) is not practical, the employer shall ensure compliance with the following:
(A) The operator shall be qualified, and
(B) The operator maintains a safe distance from the point of operation through the use of hand tools or the size and/or shape of the material being worked so that the operator's hands never enter the point of operation.
(c) Inch. The inch operating means shall be designed to prevent exposure of the worker's hands within the point of operation.
(d) Point of operation guards and devices shall comply with applicable sections of this Article.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4225. Definitions.
s 4226. Definitions.
Note: Authority cited: Section 142.3, Labor Code.
s 4227. Metal Shears.
(a) Mechanical power and foot and hand power metal shears shall be provided with a guard which will prevent the hands of the operator from entering the zone traveled by the knives of the shears while they are in motion. This guard may be a fixed barrier, set not more than 3/8-inch above the table (or in accordance with Figure G-8 and Table G-3 of Section 4186), or a self-adjusting barrier with a limit of 3/8-inch above the table, but that will automatically rise to the thickness of the material.
(b) Automatic clamps of "hold-downs" on metal shears, when cutouts are filled in with plastic or screen, will be acceptable as a guard. Hydraulic or pneumatic hold-downs shall be guarded by U shaped guards coming down to provide a clearance of not more than 3/8-inch between the table and the bottom of the guard or by other means or methods which will provide equivalent protection for the employee.
(c) When metal shears are guarded by means of a strip of heavy metal in front of the knife, the strip shall be set at such an angle with the table that the cutting line will be visible to the operator.
(d) Partial enclosure guards shall be provided to prevent operator(s) or helper(s) from reaching around or behind the guard and into the point of operation.
(e) Chains, barriers or other means of guarding shall be provided to prevent entry to the rear of the shear during operation.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4228. Metal Embossing Machines (Class B).
Metal embossing machines shall be guarded at the point of operation in the same manner as power presses or rolls, or shall be provided with a feed which does not require the hands of the operator to come into contact with die while feeding.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4229. Nonrepeat Device (Class A).
s 4230. Treadle Controls.
(a) The treadle control return spring(s) shall be of the compression type designed to prevent interleaving of spring coils in event of breakdown.
(b) Where practical, each machine simultaneously attended or operated by more than one employee shall be equipped with a treadle control for each employee exposed to the point of operation hazards.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4231. Circular Metal-Cutting Saws (Class B).
(a) Circular metal-cutting saws shall be provided with a hood which will cover the saw to at least the depth of the teeth.
The hood shall automatically adjust itself to the thickness of and remain in contact with the material being cut at the point where the stock encounters the saw, or
(b) There shall be a fixed or manually adjusted hood or guard provided the space between the bottom of the guard and the material being cut does not exceed three-eighths inch, or
(c) The saw shall be covered with a horizontally sliding guard or an enclosure with an opening through which the stock will pass, if the material to be cut is in the form of angles, T-bars, Z-bars or other shapes which cannot pass under the guards named in (a) and (b).
Exceptions:
1. Saws used for cutting hot metal and saws with periphery speed less than 500 feet per minute.
2. Stereotype saws, electrotype saws and similar saws used for cutting zinc, copper or brass plate, or soft metals, if a laminated safety glass shield or similar barrier is provided above the saw, so placed as to afford protection to the operator.
(d) The exposed parts of the saw blade under the table shall be guarded.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4232. Rolls (Class B).
s 4233. Bar Stock Machine (Class A).
On machines where revolving bar stock is being machined, that portion of the bar stock which extends beyond the machine shall be guarded by a trough or tube or by other effective means.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4234. Wire Drawing Machines (Class B).
(a) Blocks shall be equipped with a stopping device so arranged that it will automatically shut down the block in case the operator should be caught on the block and be carried around it, or
(b) A device along the operating side of a continuous drawing frame or unit so designed that pressure against the device will initiate instantly the process of stopping the machine.
(c) Reels shall be equipped with a stopping device so arranged that it will automatically shut down the block in case the operator should be caught in the wire as it runs from the reel, or in case the reel should be drawn up to the frame.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4235. Planers (Class A).
Openings in the bed of all metal planers shall be covered with substantial metal or other suitable covering.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4236. Alligator Shears (Class B).
(a) Guards or devices shall be provided to prevent inadvertent entry of any part of the operator's body into the point of operation or hold down.
(b) The horizontal bar or hold down shall be secured to the lower jaw, parallel to the cutting edge, at a height sufficient to permit the passage of the thickest material to be cut, and so placed as to prevent material being cut from flying up.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4237. Abrading, Buffing and Polishing Machines (Class A).
(a) Exposed arbors shall be guarded.
(b) Arbor ends which are not equipped with acorn nuts or equivalent shall be guarded.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4238. Tumbling Barrels (Class A).
(a) Tumbling barrels shall be completely enclosed or guarded by movable guardrails or by other suitable and effective means and shall be equipped with an interlock so installed that the drum cannot turn unless the guard is in place.
(b) If enclosed, tumbling barrels shall be equipped with an effective lock or brake.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4239. Forging Machines.
(a) Definitions.
Bolt-Headers. The same as an upsetter or forging machine except that the diameter of stock fed into the machine is much smaller, i.e., commonly three-fourths inch or less.
Drop Hammers. Drop hammer means a hammer in which the force of the blow is developed entirely by gravity.
Forging Presses. A class of forging equipment wherein the shaping of metal between dies is performed by mechanical or hydraulic pressure, and usually is accomplished with a single work stroke of the press for each die station.
Forging. The product of work on metal formed to a desired shape by impact or pressure in hammers, forging machines (upsetters), presses, rolls, and related forming equipment. Forging hammers, counterblow equipment and high-energy-rate forging machines impart impact to the workpiece, while most other types of forging equipment impart squeeze pressure in shaping the stock.
Forging Rolls. A class of auxiliary forging equipment wherein stock is shaped between power driven rolls bearing contoured dies. Usually used for preforming, roll forging is often employed to reduce thickness and increase length of stock.
High-Energy-Rate Forging Machines. A class of forging equipment wherein high ram velocities resulting from the sudden release of a compressed gas against a free piston impart impact to the workpiece.
Open Frame hammers (or Black-Smith Hammers). Hammers used primarily for the shaping of forgings by means of impact with flat dies. Open frame hammers generally are so constructed that the anvil assembly is separate from the operating mechanism and machine supports; it rests on its own independent foundation. Certain exceptions are forging hammers made with frame mounted on the anvil; e.g., the smaller, single-frame hammers are usually made with the anvil and frame in one piece.
Ring Rolls. A class for forging equipment used for shaping weldless rings from pierced discs or thick-walled, ring-shaped blanks between rolls which control wall thickness, ring diameter, height and contour.
Rivet Making Machines. The same as upsetters and bolt headers when producing rivets with stock diameter of 1-inch or more. Rivet making with less than 1- inch diameter is usually a cold forging operation, and therefore not included.
Steam Hammers. A type of drop hammer where the ram is raised for each stroke by a double-action steam cylinder and the energy delivered to the workpiece is supplied by the velocity and weight of the ram and attached upper die driven downward by steam pressure. Energy delivered during each stroke may be varied.
Trimming Presses. A class of auxiliary forging equipment which removes flash or excess metal from a forging. This trimming operation can also be done cold, as can coining, a product sizing operation.
Upsetters (or Forging Machines, or Headers). A type of forging equipment, related to the mechanical press, in which the main forming energy is applied horizontally to the workpiece which is gripped and held by prior action of the dies.
(b) General.
(1) Thermostatic control of heating elements for lead melting shall be provided to maintain proper melting temperature (620 to 700 degrees Fahrenheit) and prevent overheating.
(A) A covered container shall be provided to store dross skimmings.
(B) Equipment shall be kept clean, particularly from accumulations of yellow lead oxide.
(c) Drop Hammers.
(1) Drop hammers shall be equipped with safety stops which will hold the hammer in the elevated position.
(2) Stops shall be of a design that requires the hammer to be lifted to release the safety stops.
(3) The ram shall be blocked when dies are being changed or other work is being done on the hammer. Blocks or wedges shall be made of material the strength and construction of which meet or exceed the specifications and dimensions shown in Table FM-1.
_______________________________________________________________________________
_______________________________________________________________________________
TABLE FM-1-STRENGTH AND DIMENSIONS FOR WOOD RAM PROPS
_______________________________________________________________________________
Size of ... Square .... Minimum
allow- ... Maximum
static ........... Maximum Maximum
recom-
timber .... inches in . able
crushing . load within
short .... Safety mended allowable
weight
of
inches
[FN1] ... cross
section . strength
parallel . column
range
[FN2] .... factor forging length of
hammer
to grain,
p.s.i.
[FN2] ......................... for timber timber,
used inches
_______________________________________________________________________________
4 x 4 .... 16 ........ 5,000 ...... 80,000 ..... 10 8,000 44
6 x 6 .... 36 ........ 5,000 ...... 180,000 .... 10 18,000 66
8 x 8 .... 64 ........ 5,000 ...... 320,000 .... 10 32,000 88
10 x 10 ... 100 ....... 5,000 ...... 500,000 .... 10 50,000 100
12 x 12 ... 144 ....... 5,000 ...... 720,000 .... 10 72,000 132
_______________________________________________________________________________
[FN1] Actual dimension.
[FN2] Adapted from U.S. Department of Agriculture Technical Bulletin 479.
Hardwoods recommended are those whose ultimate crushing strengths in
compression parallel to grain are 5,000 p.s.i. (pounds per square inch) or
greater.
[FN3] Slenderness ratio formula for short columns is L/d = 11, where L = length
of timber in inches and d = least dimension in inches; this ratio should not
exceed 11.
(4) To prevent kickback injury tong handles shall be of sufficient length to permit them to be held at either side of the employee.
(5) Tongs shall have blunt handle ends.
(6) Where required, oil swabs, or scale removers, or other devices to remove scale shall be provided. These devices shall be long enough to enable employees to reach the full length of the die without placing hand or arm between the dies.
(7) Die keys and shims shall be made from a grade of material that will not unduly crack or splinter.
(8) All manually operated valves and switches shall be clearly identified and readily accessible.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4240. Power-Driven and Air-Lift Hammers.
(a) Every steam or air-lift hammer shall have a safety cylinder head to act as a cushion if the rod should break or pull out of the ram.
(b) Air-lift and steam hammers shall be provided with a quick closing emergency valve in the admission pipeline at a convenient location. This valve shall be closed and locked in the off position while the hammer is being adjusted, repaired, or serviced, or when the dies are being changed.
(c) Steam hammers shall be provided with a means of cylinder draining. Air-lift hammers shall be provided with two drain cocks; one on main head cylinder and one on clamp cylinder.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4241. Board Drophammers.
A suitable enclosure shall be provided to prevent damaged or detached boards from falling. The board enclosure shall be securely fastened to the hammer.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4242. Mechanical and Hydraulic Forging and Hot Trimming Presses.
(a) When dies are being changed or maintenance is being performed on the press, the following shall be accomplished:
(1) The power to the press shall be locked out in accordance with Section 3314.
(2) The flywheel shall be at rest.
(3) The ram shall be blocked with a material the strength of which shall meet or exceed the specifications or dimensions shown in Table FM-1.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4243. Inspection and Maintenance.
(a) It shall be the responsibility of the employer to maintain all forge shop equipment in a condition which will insure continued safe operation. This responsibility includes:
(1) Establishing periodic and regular maintenance safety inspections and keeping certification records of these inspections which include the date of the inspection, the signature of the person who performed the inspection, and the serial number or other identifier of the forging machine which was inspected.
(2) Scheduling and recording inspection of guards and point of operation protection devices at frequent and regular intervals. Recording of inspections shall be in the form of a certification record which includes the date the inspection was performed, the signature of the person who performed the inspection, and the serial number or other identifier of the equipment inspected.
(3) When rings or equivalent devices for locking tongs are used they shall be inspected periodically to insure safe condition.
(4) All overhead parts shall be fastened or protected in such a manner that they will not fly off or fall in event of failure.
(5) Tongs shall be maintained in a safe condition and at the proper hardness level for the job.
(6) Training personnel for the proper inspection and maintenance of forging machinery and equipment. The worker shall be instructed in the proper body position when using tongs.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4260. Hot Chamber Machine Controls.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4261. Hot Chamber and Cold Chamber Machine Controls.
Every hot and cold chamber die casting machine shall be equipped with one of the following controls:
(a) Two-hand controls requiring the concurrent use of both hands until the die is completely closed. Removal of either or both hands during the closing of the die will stop or reverse the closing cycle, or
(b) A single control of the constant pressure type. This control shall be located at such a distance from the parting line of the die that the operator cannot reach into the die at the parting line with his free hand. Removal of the hand from the control during the closing of the die will stop or reverse the closing cycle, or
(c) A sliding gate guard which when closed will prevent contact by the operator with the die. This gate shall be interlocked with the control system so that if the gate is opened prior to the completion of the closing cycle, the closing cycle will stop or reverse, or
(d) Any other device that will provide protection equivalent to that of (a), (b) or (c).
(e) On cold chamber machines two-hand controls requiring the concurrent use of both hands until the die is within 2 inches of complete closing. This control shall be of the type that has an interlocking limit switch that maintains a closed circuit for the last 2 inches of the closing cycle. Removal of either or both hands before the activation of the limit switch will stop or reverse the closing cycle.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4262. Ladling Operations.
To activate the plunger in the shot sleeve, a single control shall be provided. This control shall be a type which permits the operator to use his free hand for lading metal. The control shall be so guarded by a shield or recessed so that it cannot be activated by any part of the body other than the hand.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4263. Hot and Cold Chamber Machines. Helpers Protection.
Where a helper is employed, his position shall be protected by:
(a) A fixed barrier guard with controls. The control may be foot-operated and shall be interlocked with the primary control so that the machine cannot be started while the secondary control is activated. If the secondary control is activated during the closing cycle, the closing cycle will stop or reverse; or
(b) A sliding gate guard which when closed will prevent contact by the helper with the die. This gate shall be interlocked with the primary control system so that the machine cannot be started while the gate is open and if the gate is opened while the die is closing, the closing cycle will stop or reverse; or
(c) Two-hand controls connected with the primary controls and requiring simultaneous use of both hands of the helper before the machine can be started. Removal of one or both hands during the closing cycle will stop or reverse the closing cycle; or
(d) A single control of the constant pressure type connected with the primary controls. This control shall be located at such a distance from the parting line of the die that the helper cannot reach into the die at the parting line with his free hand. Removal of the hand from the control during the closing of the die will stop or reverse the closing cycle.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4264. Plunger Control.
(a) Every plunger on hot chamber machines shall be equipped with a control interlocked with the die which will prevent the operation of the plunger prior to the closing of the die.
(b) Every plunger on cold chamber machines shall be equipped with a control interlocked with the die which will prevent the operation of the plunger unless the die is completely open or completely closed.
(c) For the removal of a stuck plug a cold chamber machine shall be equipped with two-hand controls, which operate the plunger only, and require concurrent use of both hands.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4265. Shields for Die Casting Machines.
Each die casting machine shall be shielded in a manner which will prevent molten material from striking employees.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4266. Holding Furnaces.
An open holding furnace, the top of which is less than 30 inches from the floor or working level, shall be guarded to prevent an employee from inadvertently entering the danger area.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4296. General.
(a) Combs (featherboards) or suitable jigs shall be provided at the workplace for use when a standard guard cannot be used, as in dadoing, grooving, jointing, moulding, and rabbeting.
(b) An automatic cut-off saw which strokes continuously shall not be used if the operator is exposed to the hazards of the saw and is not able to control each stroke.
(c) Arbors and mandrels shall be constructed so as to have firm and secure bearing and be free from play.
(d) Sharpening or tensioning of saw blades or cutters shall be done only by persons with experience and skill in this kind of work.
(e) Saw frames or tables shall be constructed with lugs cast on the frame or with an equivalent means to limit the size of the saw blade that can be mounted, so as to avoid overspeed caused by mounting a saw blade larger than intended.
(f) Circular saw fences shall be so constructed than they can be firmly secured to the table or table assembly without changing their alignment with the saw. For saws with tilting tables or tilting arbors the fence shall be so constructed that it will remain in a line parallel with the saw blade, regardless of the angle of the saw blade with the table.
(g) Circular saw gauges shall be so constructed as to slide in grooves or tracks that are accurately machined, to insure exact alignment with the saw blade for all positions of the guide.
(h) Hinged saw tables shall be so constructed that the table can be firmly secured in any position and in true alignment with the saw blade.
(i) Ripsaw spreaders shall be made of hard tempered steel, or its equivalent, and shall be thinner than the saw kerf. The spreader shall be of sufficient width to provide adequate stiffness or rigidity to resist any reasonable side thrust or blow tending to bend or throw it out of position.
(j) Ripsaw spreaders shall be attached so as to remain in true alignment with the saw blade even when either the blade or table is tilted, and shall be placed so that there is not more than 1/2-inch space between the spreader and the back of the saw blade when the largest blade is mounted in the machine. The provision of a spreader in connection with grooving, dadoing, or rabbeting is not required. On the completion of such operations, the spreader shall be immediately replaced.
(k) The hood shall be made of adequate strength to resist blows and strains incidental to reasonable operation, adjusting, and handling, and shall be so designed as to protect the operator from flying splinters and broken saw teeth. It shall be made of material that is soft enough so that it will be unlikely to cause tooth breakage.
( l ) The hood shall be so mounted as to insure that its operation will be positive, reliable, and in true alignment with the saw blade; and the mounting shall be adequate in strength to resist any reasonable side thrust or other force tending to throw it out of line.
(m) For all circular saws where conditions are such that there is a possibility of contact with the portion of the saw blade either beneath or behind the table, that portion of the blade shall be covered with an exhaust hood, or, if no exhaust system is required, with a guard that shall be so arranged as to prevent accidental contact with the saw blade.
(n) Revolving double arbor saw blades shall be fully guarded in accordance with all the requirements for circular crosscut saws or with all the requirements for circular ripsaws, according to the kind of saws mounted on the arbors.
(o) No saw blade, cutter head, or tool collar shall be placed or mounted on a machine arbor unless the tool as been accurately machined to size and shape to fit the arbor.
(p) Each machine shall be designed, constructed and mounted in a manner that will eliminate hazardous vibration at any operating speed while using any tool designed for the machine.
(q) On machinery and equipment where injury might result if motors were to automatically restart after power failures, provision shall be made to prevent machines and equipment from automatically starting upon restoration of power.
Exception: Portable power tools intended to be handheld during use.
Note: For the purpose of subsection (q), the term "provision" means electrical or mechanical device, or administrative procedures.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4297. Definitions.
Block. A short block of wood, provided with a handle similar to that of a plane and a shoulder at the rear end, which is used for pushing short stock over revolving cutters.
Push stick. A narrow strip of wood or other soft material with a notch cut into one end and which is used to push short pieces of material through saws.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4298. Hog Mills.
(a) To minimize jamming, hog mills shall be provided with feed chutes and conveyors designed to handle the material being processed.
(b) Chutes shall be arranged so that the distance from any place on the rim to the cutter knives is no less than 40 inches.
(c) The feed chutes shall be provided with suitable baffles, screens, or barriers which shall prevent material being thrown from the mill.
(d) The top rim of the chute shall extend no less than 36 inches above the floor or working platform, unless the chute opening is protected by other adequate means.
(e) Employees feeding or tending hog mills shall be provided with and required to use safety belts and lines, unless they are otherwise protected from falling into the mill.
(f) All conveyor-fed hog mills shall be equipped with a trip bar, or emergency stop, located where employees can readily reach it to immediately stop the conveyors. A metal detector shall be installed whenever possible.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4299. Brush and Slash Chippers.
(a) Access panels for maintenance and adjustment shall be closed and secured prior to operation of brush chippers.
(b) Each rotary drum or disk-type chipper not equipped with a mechanical infeed system shall be equipped with an infeed hopper not less than 85 inches, measured from the blades or knives to ground level or working level over the centerline of the hopper, and shall have sufficient height on its side members so as to prevent personnel from contacting the blades or knives of the machine during normal operations.
(c) Each rotary drum or disk-type chipper not equipped with a mechanical infeed system shall have a flexible anti-kickback device installed in the infeed hopper for the purpose of protecting the operator and other persons in the machine area from the hazards of flying chips and debris.
(d) Each disk-type chipper equipped with a mechanical infeed system shall have a quick stop and reversing device on the infeed. The activating lever for the quick stop and reversing device shall be located within easy reach of the operator.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4300. Circular Ripsaws Manual Feed (Class B).
(a) Each circular hand-fed ripsaw shall be guarded by a hood which shall completely enclose that portion of the saw blade above the table and that portion of the blade above the material being cut.
(b) The hood shall automatically adjust itself to the thickness of and remain in contact with the material being cut at the point where the stock encounters the saw blade, or
(c) The hood may be a fixed or manually adjusted hood or guard provided the space between the bottom of the guard and the material being cut does not exceed 1/2 inch.
(d) The hood or other guard shall be so designed as to prevent a "kickback," or a separate attachment that will prevent a "kickback" shall be provided. "Anti-kickback" devices shall be designed to be effective for all thicknesses of material.
(e) Except when grooving, dadoing or rabbeting, a spreader shall be provided and fastened securely to the saw. It shall be designed and installed in accordance with the Provisions of Section 4296.
(f) A push stick of suitable design shall be provided and used.
Note: Authority cited: Section 142.3, Labor Code. Reference: Section 142.3, Labor Code.
s 4301. Self-Feed Circular Ripsaws.
(a) In addition to guards over blades as specified in Section 4296, feed rolls shall be protected by a hood or guard to prevent the hands of the operator fromcoming in contact with the in-running rolls at any point. (continued)