T, stopping time of the press measured at approximately 90° position of crankshaft rotation (seconds).

Guards shall be used to protect all areas of entry to the point of operation not protected by the presence sensing device.

(iv) The pull-out device shall protect the operator as specified in paragraph (c)(3)(i)(b) of this section, and shall inIclude attachments for each of the operator's hands.

(a) Attachments shall be connected to and operated only by the press slide or upper die.

(b) Attachments shall be adjusted to prevent the operator from reaching into the point of operation or to withdraw the operator's hands from the point of operation before the dies close.

(c) A separate pull-out device shall be provided for each operator if more than one operator is used on a press.

(d) Each pull-out device in use shall be visually inspected and checked for proper adjustment at the start of each operator shift, following a new die setup, and when operators are changed. Necessary maintenance or repair or both shall be performed and completed before the press is operated. Records of inspections and maintenance shall be kept in accordance with paragraph (e) of this section.

(v) The sweep device may not be used for point of operation safeguarding after December 31, 1976.

(vi) A holdout or a restraint device shall protect the operator as specified in paragraph (c)(3)(i)(c) of this section and shall include attachments for each of the operator's hands. Such attachments shall be securely anchored and adjusted in such a way that the operator is restrained from reaching

into the point of operation. A separate set of restraints shall be provided for each operator if more than one operator is required on a press.

(vii) The two hand control device shall protect the operator as specified in paragraph (c)(3)(i)(e) of this section.

(a) When used in press operations requiring more than one operator, separate two hand controls shall be provided for each operator, and shall be designed to require concurrent application of all operators' controls to activate the slide. The removal of a hand from any control button shall cause the slide to stop.

(b) Each two hand control shall meet the construction requirements of paragraph (b)(7)(v) of this section.

(c) The safety distance (D) between each two hand control device and the point of operation shall be greater than the distance determined by the following formula:

where:

D.=63 inches/second X T.;

D.=minimum safety distance (inches); 63 inches/second-hand speed constant;

and

T, stopping time of the press measured at approximately 90° position of crankshaft rotation (seconds).

(d) Two hand controls shall be fixed in position so that only a supervisor or safety engineer is capable of relocating the controls.

(viii) The two hand trip device shall protect the operator as specified in paragraph (c)(3)(i)(e) of this section.

(a) When used in press operations requiring more than one operator, separate two hand trips shall be provided for each operator, and shall be designed to require concurrent application of all operators' to activate the slide.

(b) Each two hand trip shall meet the construction requirements of paragraph (b)(6) of this section.

(c) The safety distance (Dm) between the two hand trip and the point of operation shall be greater than the distance determined by the following formula:

Dm-63 inches/second X Tmi

where:

Dm minimum safety distance (inches); 63 inches/second-hand speed constant;

and

Tm the maximum time the press takes for the die closure after it has been tripped (seconds). For full revolution clutch presses with only one engaging point Tm is equal to the time necessary for one and one-half revolutions of the crankshaft. For full revolution clutch presses with more than one engaging point, Tm shall be calculated as follows:

Im

=

[2+ (1 Number of engaging points per revolution)] × time necessary to complete one revolution of the crankshaft (seconds).

(d) Two hand trips shall be fixed in position so that only a supervisor or safety engineer is capable of relocating the controls.

(4) Hand feeding tools. Hand feeding tools are intended for placing and removing materials in and from the press. Hand feeding tools are not a point of operation guard or protection device and shall not be used in lieu of the "guards" or devices required in this section.

(5) Additional requirements for safeguarding. Where the operator feeds or removes parts by placing one or both hands in the point of operation, and a two hand control, presence sensing device of Type B gate or movable barrier (on a part revolution clutch) is used for safeguarding:

(i) The employer shall use a control system and a brake monitor which comply with paragraphs (b) (13) and (14) of this section. This requirement shall be complied with by November 1, 1975;

(ii) The exception in paragraph (b) (7)(v)(d) of this section for two hand controls manufactured and installed before August 31, 1971 is not applicable under this paragraph (c)(5);

(iii) The control of air clutch machines shall be designed to prevent a significant increase in the normal stopping time due to a failure within the operating valve mechanism, and to inhibit further operation if such failure does occur, where a part revolution clutch is employed. The exception in paragraph (b)(7)(xi) of this section for controls manufactured and installed before August 31, 1971, is not applicable under this paragraph (c) (5).

(d) Design, construction, setting and feeding of dies-(1) General requirements. Effective February 1, 1975, the employer shall: (i) Use dies and operating methods designed to control or eliminate hazards to operating personnel, and (ii) furnish and enforce the use of hand tools for freeing and removing stuck work or scrap pieces from the die, so that no employee need reach into the point of operation for such purposes.

(2) [Reserved]

(3) Scrap handling. The employer shall provide means for handling scrap from roll feed or random length stock operations. Scrap cutters used in conjunction with scrap handling systems shall be safeguarded in accordance with paragraph (c) of this section and with § 1910.219.

(4) Guide post hazard. The hazard created by a guide post (when it is located in the immediate vicinity of the operator) when separated from its bushing by more than one-fourth inch shall be considered as a point of operation hazard and be protected in accordance with paragraph (c) of this section.

(5) Unitized tooling. If unitized tooling is used, the opening between the top of the punch holder and the face of the slide, or striking pad, shall be safeguarded in accordance with the requirements of paragraph (c) of this section.

(6) Tonnage, stroke, and weight designation. All dies shall be:

(1) Stamped with the tonnage and stroke requirements, or have these characteristics recorded if these records are readily available to the die setter;

(ii) Stamped to indicate upper die weight when necessary for air counterbalance pressure adjustment; and

(iii) Stamped to indicate complete die weight when handling equipment may become overloaded.

(7) Die fastening. Provision shall be made in both the upper and lower shoes for securely mounting the die to the bolster and slide. Where clamp caps or setscrews are used in conjunction with punch stems, additional means of securing the upper shoe to the slide shall be used.

(8) Die handling. Handling equipment attach points shall be provided on all dies requiring mechanical handling.

(9) Diesetting. (i) The employer shall establish a diesetting procedure that will insure compliance with paragraph (c) of this section.

(ii) The employer shall provide spring loaded turnover bars, for presses designed to accept such turnover bars.

(iii) The employer shall provide die stops or other means to prevent losing control of the die while setting or removing dies in presses which are inclined.

(iv) The employer shall provide and enforce the use of safety blocks for use whenever dies are being adjusted or repaired in the press.

(v) The employer shall provide brushes, swabs, lubricating rolls, and automatic or manual pressure guns so that operators and diesetters shall not be required to reach into the point of operation or other hazard areas to lubricate material, punches or dies.

and (e) Inspection, maintenance, modification of presses—(1) Inspection and maintenance records. (i) It shall be the responsibility of the employer to establish and follow a program of periodic and regular inspections of his power presses to insure that all their parts, auxiliary equipment, and safeguards are in a safe operating condition and adjustment. The employer shall maintain records of these inspections and the maintenance work performed.

(ii) Each press shall be inspected and tested no less than weekly to determine the condition of the clutch/ brake mechanism, antirepeat feature and single stroke mechanism. Necessary maintenance or repair or both shall be performed and completed before the press is operated. The employer shall maintain records of these inspections and the maintenance work

performed. These requirements do not apply to those presses which comply with paragraphs (b) (13) and (14) of this section.

(2) Modification. It shall be the responsibility of any person modifying a power press to furnish instructions with the modification to establish new or changed guidelines for use and care of the power press so modified.

(3) Training of maintenance personnel. It shall be the responsibility of the employer to insure the original and continuing competence of personnel caring for, inspecting, and maintaining power presses.

(f) Operation of power presses—(1) Employment of minors. The employer shall permit no one under 18 years of age to operate or assist in the operation of machinery covered in this section, except that this paragraph shall not be deemed to prohibit the employment of persons who are 16 or 17 years of age in an apprenticeship training program which meets the requirements contained in §§ 570.59 and 570.50 (b) and (c) of this title.

(2) Instruction to operators. The employer shall train and instruct the operator in the safe method of work before starting work on any operation covered by this section. The employer shall insure by adequate supervision that correct operating procedures are being followed.

(3) Work area. The employer shall provide clearance between machines so that movement of one operator will not interfere with the work of another. Ample room for cleaning machines, handling material, work pieces, and scrap shall also be provided. All surrounding floors shall be kept in good condition and free from obstructions, grease, oil, and water.

(4) Overloading. The employer shall operate his presses within the tonnage and attachment weight ratings specified by the manufacturer.

Explanation of above diagram:

This diagram shows the accepted safe openings between the bottom edge of a guard and feed table at various distances from the danger line (point of operation).

The clearance line marks the distance required to prevent contact between guard and moving parts.

The minimum guarding line is the distance between the infeed side of the guard and the danger line which is one-half inch from the danger line.

The various openings are such that for average size hands an operator's fingers won't reach the point of operation.

After installation of point of operation guards and before a job is released for operation a check should be made to verify that the guard will prevent the operator's hands from reaching the point of operation.

(g) Reports of injuries to employees operating mechanical power presses. (1) The employer shall, within 30 days of the occurrence, report to either the Director of the Office of Standards Development, OSHA, U.S. Department of Labor, Washington, D.C. 20210, or the State agency administering a plan approved by the Assistant Secretary of Labor for Occupational Safety and Health, all point of operation injuries to operators or other employees. The following information shall be included in the report:

(i) Employer's name, address and location of the workplace (establishment).

(ii) Employee's name, injury sustained, and the task being performed (operation, set-up, maintenance, or other).

(iii) Type of clutch used on the press (full revolution, part revolution, or direct drive).

(iv) Type of safeguard(s) being used (two hand control, two hand trip, pullouts, sweeps, or other). If the safeguard is not described in this section, give a complete description.

(v) Cause of the accident (repeat of safeguard failure, removing press, stuck part or scrap, no safeguard provided, no safeguard in use, or other).

(vi) Type of feeding (manual with hands in dies or with hands out of dies, semiautomatic, automatic, or other).

(vii) Means used to actuate press stroke (foot trip, foot control, hand trip, hand control, or other).

(viii) Number of operators required for the operation and the number of operators provided with controls and safeguards.

OMB CONTROL No. 1218-0050. (47 FR 14696, Apr. 6, 1982)

(Secs. 4(b)(2), 6(b), 8(c), Pub. Law 91-596, 84 Stat. 1592, 1593, 1599 (29 U.S.C. 653, 655, 657), Secretary of Labor's Order No. 12-71 and 8-76, 36 FR 8754, 41 FR 25059; 29 CFR Part 1911)

[39 FR 32502, June 27, 1974, as amended at 39 FR 41846, Dec. 23, 1974; 40 FR 3982, Jan. 27, 1975; 43 FR 49750, Oct. 24, 1978; 45 FR 8594, Feb. 8, 1980; 47 FR 14696, Apr. 6, 1982]

§ 1910.218 Forging machines.

(a) General requirements—(1) Use of lead. The safety requirements of this subparagraph apply to lead casts or other use of lead in the forge shop or die shop.

(i) Thermostatic control of heating elements shall be provided to maintain proper melting temperature and prevent overheating.

(ii) Fixed or permanent lead pot installations shall be exhausted.

(iii) Portable units shall be used only in areas where good, general room ventilation is provided.

(iv) Personal protective equipment (gloves, goggles, aprons, and other items) shall be worn.

(v) A covered container shall be provided to store dross skimmings.

(vi) Equipment shall be kept clean, particularly from accumulations of yellow lead oxide.

(2) Inspection and maintenance. 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:

(i) Establishing periodic and regular maintenance safety checks and keeping records of these inspections.

(ii) Scheduling and recording inspection of guards and point of operation protection devices at frequent and regular intervals.

(iii) Training personnel for the proper inspection and maintenance of forging machinery and equipment.

(iv) All overhead parts shall be fastened or protected in such a manner that they will not fly off or fall in event of failure.

(3) Hammers and presses. (i) All hammers shall be positioned or installed in such a manner that they remain on or are anchored to founda. tions sufficient to support them ac cording to applicable engineering standards.

(ii) All presses shall be installed in such a manner that they remain where they are positioned or they are anchored to foundations sufficient to support them according to applicable engineering standards.

Minimum

allowable

3

p.s.i.2

weight of forging hammer for timber used

length of

timber, inches