Rank: New forum user 
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Hi all, wondering if anyone has any information relevant to a project I am currently working on. I have been tasked with enclosing a pallet conveyor system, which is currently unguarded around the perimeter. Client wants the area enclosed with 2M high guarding to avoid 'crush risks' between pallets, but I am conscious this will then create additional risks in the system being a full body access system. Have planned in captive key (fortress/castell) entry for defined/requestable entry, but would like to reference any up to date guides/regulations for full body access systems (I have a specific company version which is 2012). Any help/advice on any part of the above explanation would be most welcome. Thanks
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Rank: Super forum user
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How old is the existing conveyor system?
Are you effectively designing a new machine?
You will have to show how you meet the Essential Health and Safety Requirements of the Supply of Machinery Regulations.
BS12100 is the starting design code to consider. There is also a machine risk assessment standard to follow
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Rank: Forum user
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Please see below a useful link which then takes you through to all the associated documentation with regards to safety of machinery:
http://www.hse.gov.uk/work-equipment-machinery/essential-require.htm
You might also want to look at the British Standards series BS EN ISO 14122-2 2016 Safety of machinery - Permanent means of access to machinery with regards to minimum distances for people to access/egress from the working areas around machinery.
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Rank: Super forum user
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Machinery risk assessment is ISO14121
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Rank: Super forum user 
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Originally Posted by: Ian Bell2  Machinery risk assessment is ISO14121
Not any more Ian it's now ISO 12100, 14121 has been withdrawn. ;)
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Rank: Super forum user
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Originally Posted by: Steve Tunstall Hi all, wondering if anyone has any information relevant to a project I am currently working on. I have been tasked with enclosing a pallet conveyor system, which is currently unguarded around the perimeter. Client wants the area enclosed with 2M high guarding to avoid 'crush risks' between pallets, but I am conscious this will then create additional risks in the system being a full body access system. Have planned in captive key (fortress/castell) entry for defined/requestable entry, but would like to reference any up to date guides/regulations for full body access systems (I have a specific company version which is 2012). Any help/advice on any part of the above explanation would be most welcome. Thanks
There is a little more to this than just adding guarding. Firstly as it is a major modification it will need to comply with the EHSR's of the MD/SMSR. You are talking about full body access, and crushing so you are looking at fatalities, probably only one, but that still will require PLd, more likely PLe. You will need to implement the access in a safe manner, so this will likely need to stop the conveyor, otherwise there is no point in having the guarding. Things like this are difficult to assesss without seeing them to be honest. What's your role in this? You are saying the "client" wants, is the client the designer?
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Rank: Super forum user
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Paul
Read my 1st post - BS12100 mentioned as the initial design guide document. Machinery risk assessment is still ISO/TR141121-2 - still current on the BS website shop Had to buy a new copy about 3 weeks ago
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Rank: Super forum user
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Originally Posted by: Ian Bell2 Paul
Read my 1st post - BS12100 mentioned as the initial design guide document. Machinery risk assessment is still ISO/TR141121-2 - still current on the BS website shop Had to buy a new copy about 3 weeks ago
Ian, you can still buy it, yes, but, it's no longer harmonised to the Machinery Directive, thus you cannot claim a presumption of conformity by following its guidance. Check here: https://ec.europa.eu/growth/single-market/european-standards/harmonised-standards/machinery_en
Plus the document you are quoting is a Technical Report, no longer a recognised standard. ISO 12100 has been made into a single document from the two parts, and incorporates the original requirements of 14121.
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Rank: Super forum user
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12100 :2010 remains valid. TR14121-2 suggests a risk assessment methodolgy Page 15 of 12100:2010 Section 5.4 Hazard identification still references 'Several methods are available for the systematic identification of hazards. See also ISO/TR 14121-2.'
As an acceptable risk assessment method. In my first post I didn't say BS12100 would show full ESHR compliance, because it doesn't - bu as a Type A standard its a design risk assessment starting point - before Type B and/or C standards are identified.
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Rank: New forum user
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Hi guys,
Thanks for the replies, they have certainly pointed me in the right direction of reference points to ensure I cover the minimum standards (ie EHSRs). In answer to some of the questions posed through the thread :
No this is not a total machine change, as suggested, it is quite simply, adding some standard machinery guarding fences around basic pallet roller/chain conveyors (It is actually industry standard not to enclose these things and they are considered safe to use without the guarding as most sites i visit have these conveyors in use in their warehouses). The risk the client is trying to eliminate is some areas where pallets meet and could pose a crushing risk. There is an argument to say that these pallets would not actually kill someone when coming together, due to nature of the product and speed of a pallet, but I have planned to define it as a PLd area anyway to be on the safe side and I will carry out a risk assessment prior to design to be sure of this. This brings me back to my initial question of whether there is any specific guidance of full body access systems (from what you guys have suggested, it looks like there is no specific guidance for this and it comes down to design of the system and risk assessment?). Also, the machinery guarding will be specified by Client, but I have an electrical/software company who will design the safety circuit. Many thanks
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Rank: Super forum user
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Is the client creating a shear/crush hazard where these pallets enter the guarded zone? If not, then the guarding will be inadequate to prevent whole body access in the first place surely? If I was assessing a partly guarded line, then I would be questioning this as much as an unguarded line. Who is the integrator for the project because someone has to take the responsibility for the installed system. This is a safety product being placed independently onto the market and a such requires CE marking in its own right, check the Annexes. You won't find a B or C type standard entitled "controls for whole body access guarding", you will find the standards for minimum gaps to prevent crushing and shearing, you will find minimum & maximum guard dimensions in standards, and you will find C type standards on conveyor systems. Are these powered/free conveyors? If so the client could well be increasing the hazards with guarding. Edited by user 01 November 2018 17:55:13(UTC)
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