Machine Guarding in Ontario: Regulations, PSRs and Engineering Assessments

What Is Machine Guarding?

Machine guarding refers to barriers, devices, controls, and other protective measures used to help prevent workers from accessing hazardous areas of machinery.

The appropriate method depends on the machine, its operating cycle, the hazards present, and how workers interact with the equipment. Safeguarding should consider not only normal production but also activities such as setup, cleaning, adjustment, troubleshooting, and maintenance.

Enhancing Workplace Safety: A Comprehensive Guide to Machine Guarding in Ontario

Machine Guarding Ontario: Regulatory Framework and Compliance

Ontario Regulation 851: Safeguarding Machinery

Ontario Regulation 851 sets forth stringent requirements for safeguarding machinery in industrial establishments. Compliance with these regulations is mandatory for employers to ensure worker safety. Regular compliance checks and audits are conducted to verify adherence to these standards. Access the regulation here.

CSA Z432-23: Safeguarding of Machinery

The CSA Z432-23 standard provides comprehensive guidelines for the safeguarding of machinery in Canada, including Ontario. It offers recommendations for the design, installation, and maintenance of machine guards to mitigate risks to workers. Compliance with CSA Z432-23 is essential for ensuring workplace safety and regulatory compliance. Learn more about the standard here.

Compliance Initiatives and Results

The Ontario government conducts regular compliance initiatives to assess adherence to machine guarding regulations. Employers must comply with these initiatives to maintain a safe work environment and avoid penalties. Access the latest compliance initiative results here.

Common Machine Hazards

Machine hazards can occur anywhere workers may come into contact with hazardous movement or machine components. Identifying these hazards is an important part of determining where guarding or other safeguarding measures may be appropriate.

Pinch Points

Pinch points can occur where a person could become caught between moving components or between a moving component and a stationary object.

Nip Points

In-running nip points can occur where rotating components move toward one another or where a rotating component can draw clothing, fingers, hands, or other body parts into the machinery.

Crush Points

Crush hazards can exist where machine components move toward fixed surfaces or other components, creating an area where a worker could become trapped or injured.

Cutting and Shearing Hazards

Blades, presses, cutters, and other moving components can create cutting or shearing hazards at the point of operation or elsewhere on the machine.

Rotating Equipment

Exposed shafts, couplings, spindles, gears, pulleys, and other rotating components may present contact or entanglement hazards.

Unexpected Startup

Unexpected startup or movement can expose workers to hazardous machine motion, particularly during cleaning, adjustment, troubleshooting, or maintenance. Machine guarding does not replace appropriate hazardous energy control or lockout procedures where those measures are required.

Access During Maintenance

A safeguard designed for normal production may not address every hazard encountered when a worker needs access to machinery for maintenance, cleaning, setup, or troubleshooting. These interactions should also be considered when assessing machine hazards.

Ontario Machine Guarding Requirements

Machine guarding requirements for Ontario industrial establishments are addressed through the Occupational Health and Safety Act and Ontario Regulation 851 – Industrial Establishments. Requirements vary depending on the machinery, hazards, and safeguarding measures involved.

Industry standards such as CSA Z432 – Safeguarding of Machinery may also provide guidance when assessing or designing safeguards. The appropriate approach should be based on the specific equipment, hazards, and application.

Machine Guarding vs. Machine Safeguarding

The terms machine guarding and machine safeguarding are often used interchangeably, but machine safeguarding generally describes the broader approach to protecting workers from machinery hazards.

Machine guarding commonly refers to physical guards or barriers that restrict access to hazardous machine components.

Machine safeguarding may include a wider range of protective measures, such as:

• Fixed and movable guards
• Interlocking devices
• Light curtains and other presence sensing devices
• Two-hand controls
• Safety-related control functions
• Safe-distance measures
• Hazardous energy controls
• Procedures and training

A machine safeguarding strategy may use several protective measures together depending on the hazards and how workers interact with the equipment.

Types of Machine Safeguards

1. Fixed Guards

Fixed guards are permanent physical barriers that enclose hazardous areas of machinery, preventing access during operation. They are securely mounted and cannot be easily removed or bypassed by workers. Source: Ontario Regulation 851: Safeguarding Machinery

2. Interlocking Guards

Interlocking guards feature mechanisms that prevent machinery from operating unless the guard is securely in place. These guards enhance safety by ensuring that workers cannot access hazardous areas while the machinery is in operation. Source: CSA Z432-23: Safeguarding of Machinery

3. Presence Sensing Devices

Presence sensing devices detect the presence of workers within hazardous zones and automatically stop the machinery to prevent accidents. They utilize various technologies such as light curtains, laser scanners, and proximity sensors to monitor worker proximity to machinery.

Light curtains require careful consideration of the machine, hazard location, stopping performance, and how workers can approach the hazardous area. Where these systems incorporate muting functions, additional control considerations may apply. Learn more about light curtain muting configurations.

4. Two-Hand Controls

Two-hand controls require simultaneous activation by both hands, ensuring that operators keep their hands away from dangerous areas during machine operation. This safeguarding method provides an additional layer of protection against accidental contact with moving parts.

5. Adjustable Guards

Adjustable guards can be customized to fit different machinery and operational requirements. They offer flexibility while maintaining safety by allowing adjustments to accommodate varying workpiece sizes and machine configurations.

When Can Machine Guarding Trigger a PSR/PHSR?

A Pre-Start Health and Safety Review (PSR or PHSR) may be required for certain machine safeguarding applications under Ontario Regulation 851. Item 2 addresses specific safeguarding devices and interlocked barrier guards, although not every machine guard automatically triggers a PSR.

Where required, an Item 2 PSR must be completed by a professional engineer. HITE Engineering provides Pre-Start Health and Safety Review services for Ontario facilities. PSR requirements may also apply to other equipment and processes, including lifting devices, storage structures, and certain flammable liquid or ignition hazards.

When Should You Involve a Professional Engineer?

A professional engineer may be needed where a PSR is required or a machine safeguarding issue requires technical assessment. Engineering involvement may also be appropriate when:

• Installing or modifying industrial machinery
• Adding interlocked guards or presence sensing devices
• Integrating safeguards with machine control systems
• Assessing stopping performance or safe distances
• Relocating or reconfiguring machinery
• Addressing identified guarding deficiencies
• Determining whether safeguarding changes may trigger a PSR

Involving an engineer early can help identify technical requirements before guards are fabricated or control systems are modified.

Best Practices for Machine Safeguarding

• Conduct Risk Assessments: Perform thorough risk assessments to identify potential hazards associated with machinery and prioritize safeguarding measures accordingly.
• Employee Training: Provide comprehensive training to workers on the safe operation and maintenance of machinery, including proper use of machine guards and emergency procedures.
• Regular Maintenance: Implement a regular maintenance schedule to inspect and maintain machine guards, ensuring they remain effective and free from defects or damage.
• Safety Culture: Foster a culture of safety awareness among employees, encouraging them to actively participate in identifying hazards and adhering to safety protocols.

Incorporating diverse types of machine safeguards in accordance with Ontario regulations and industry standards is crucial for ensuring workplace safety. By implementing effective safeguarding measures and adhering to best practices, employers can create a safer work environment for their employees while complying with regulatory requirements.

In the realm of machine guarding solutions, HITE Engineering Corporation stands out as the premier choice for businesses in Ontario. With a dedicated and skilled team of engineers, HITE Engineering Corporation offers unparalleled expertise to address all Machine Guarding needs. Their commitment to excellence goes beyond mere compliance with regulations – they strive to provide innovative, tailored solutions that prioritize both safety and efficiency. Choosing HITE Engineering Corporation ensures that businesses receive not just a service but a comprehensive partnership in creating a workplace environment where safety is paramount.

How HITE Engineering Can Help

HITE Engineering supports industrial facilities throughout Ontario with Machine Guarding & Safeguarding Assessment services that evaluate existing safeguards, identify deficiencies, assess proposed changes, and determine where additional engineering review may be appropriate. Facilities can also contact HITE Engineering to discuss specific equipment, hazards, or safeguarding requirements.

Machine guarding engineering support may include:

• Machine guarding and safeguarding assessments
• Machinery hazard and risk assessments
• Reviews of fixed and interlocked guarding
• Light curtain and presence sensing applications
• Assessment of proposed safeguarding modifications
• Identification of machine guarding deficiencies
• Engineering recommendations for corrective measures
• PSR/PHSR applicability assessments
• Pre-Start Health and Safety Reviews where required
• Engineering reports and documentation

FAQs

What is the difference between machine guarding and safeguarding?

Machine guarding generally refers to physical guards or barriers that restrict access to hazardous machine components. Machine safeguarding is broader and can include guards, interlocks, light curtains, presence sensing devices, controls, procedures, and other protective measures.

Do all machines need guarding?

The guarding requirements for a machine depend on the hazards it presents and how workers interact with the equipment. Different machinery may therefore require different safeguarding methods. Ontario Regulation 851 includes requirements addressing specific machinery hazards, including exposed moving parts and in-running nip points.

Who can assess machine guarding?

Facility safety personnel, equipment manufacturers, and other qualified individuals may contribute to identifying machinery hazards. A professional engineer can provide a technical engineering assessment where appropriate, and an engineer is required to conduct an Item 2 PSR when that review is required under Ontario Regulation 851.

Is machine guarding part of a PSR?

It can be. Item 2 of the Table to section 7 of Ontario Regulation 851 addresses certain machinery safeguarding arrangements. Not every guard automatically requires a PSR, so the equipment, safeguarding arrangement, circumstances, and applicable exemptions need to be considered. HITE’s Pre-Start Health and Safety Review services provide more information about this process.

How Do I Know If My Machine Guarding Needs to Be Assessed?

Some common signs that machinery or its safeguarding may need further assessment include:

• Hazardous moving components are accessible to workers
• Exposed pinch, nip, crush, cutting, or entanglement hazards are present
• Workers can reach over, under, around, or through existing guards
• Guards, interlocks, or presence sensing devices are not functioning properly
• Safeguarding devices can be bypassed or defeated
• Workers can access hazardous areas during setup, cleaning, or maintenance
• Machinery or its safeguarding system has been modified
• It is unclear whether the safeguarding arrangement could require a PSR

These conditions do not necessarily mean the machinery is non-compliant, but they may indicate that a more detailed machine guarding assessment is appropriate.