Key Considerations in Conveyor Belt Design for Safety
Personnel represent the most valuable asset in any mining or industrial operation, and prioritizing their safety and security should be the foremost consideration in conveyor belt design.
Three important elements of conveyor safety are proper training, guarding, and policies and procedures.
Engineers and designers should strive to integrate safety enhancements that maintain or enhance the functionality of conveyor systems.
While conveyor design has seen minimal evolution over time, workplace safety and accountability standards have undergone significant transformation. Regulations now encompass lifting restrictions, lockout/ tagout /blockout / testout requirements, confined-space entry protocols, and other safety procedures. However, businesses also confront mounting pressure to boost output and maintain continuous production, which can pose safety challenges.
Conveyor belt design plays a crucial role in safeguarding worker safety by incorporating industry-standard features like barrier guards and mechanisms for easier cleaning and maintenance of conveyor components. It's essential for employees to undergo thorough training to recognize potential safety risks and fulfill all qualification criteria. 
Barrier Guards
Barrier Guards are pivotal in ensuring the safe operation of conveyor belts by shielding personnel from moving parts. Many conveyor systems integrate barrier guards, or area guarding, around potential pinch points where personnel could come into contact. These guards should span the entire accessible length of the conveyor belt. They should be designed for easy installation and removal to facilitate safe and efficient maintenance by authorized service personnel, ensuring guards are reinstated after work is completed.
Effective guarding depends on the size of its opening relative to the distance from the hazard it is guarding against.
Maintenance During Operation
Given that many conveyors operate continuously, scheduled downtime is precious. Equipment failures or issues can exacerbate productivity losses and necessitate emergency cleanup and repairs, underscoring the need for prompt maintenance whenever feasible.
Global safety standards recognize that certain maintenance tasks must be conducted while equipment is operational, exempting operators from conventional shutdown requirements. These exemptions emphasize awareness and restrict maintenance to trained and authorized personnel only.
Recent safety standards, such as those outlined in ISO/EN 14121, prioritize risk-ranked rules over task-specific exemptions. These standards assess the comparative injury risks associated with servicing equipment during operation versus when it's stopped, favoring the least risky approach.
Components like belt cleaners, vital for controlling fugitive materials and carryback, often require frequent servicing to maintain conveyor efficiency. Safety concerns typically prevent servicing these components during operation, presenting maintenance challenges.
However, advancements in design can enable safe servicing of belt cleaners and other critical components while conveyors are operational. Specialized tools and training can empower authorized maintenance personnel or contractors to perform these tasks safely during belt operation.