AS1755-2000 Conveyors Safety Requirements

AS 17552000
AS 1755
Australian Standard
Accessed by DOWNER EDI LIMITED on 12 Jul 2006
ConveyorsSafety requirements
This Australian Standard was prepared by Committee EL/23, Electrical Equipment

in Coal Mines. It was approved on behalf of the Council of Standards Australia on
15 September 2000 and published on 6 November 2000.
The following interests are represented on Committee EL/23:

Australian Conveyor Manufacturers Association
Bureau of Steel Manufacturers of Australia
Department of Employment Education and Training
Department of Mineral Resources, N.S.W.
Department of Training and Industrial Relations, Qld
Metal Trades Industry Association of Australia
Minerals Council of Australia
National Safety Council of Australia
Safety Institute of Australia
State Chamber of Commerce
Testing interests
Victorian WorkCover Authority
WorkCover New South Wales
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This Standard was issued in draft form for comment as DR 97349.
AS 17552000
Australian Standard
Conveyors Safety requirements
Originated as AS C2151971.
Previous edition AS 17551986.
Third edition 2000.
COPYRIGHT
Standards Australia International
All rights are reserved. No part of this work may be reproduced or copied in any form or by any
means, electronic or mechanical, including photocopying, without the written permission of the
publisher.
Published by Standards Australia International Ltd
GPO Box 5420, Sydney, NSW 2001, Australia
ISBN 0 7337 3588 6
AS 17552000
PREFACE
This Standard is the result of consensus among representatives of the Standards Australia
Committee SF/25, Guarding of Conveyors and Joint Standards Australia/Standards New
Zealand Committee EL/23, Electrical Equipment in Coal Mines to prepare it as an
Australian Standard. It supersedes AS 17551986, ConveyorsDesign, construction,
installation and operationSafety requirements. It contains the safety measures to be
implemented for the installation and operation of conveyors and conveyor systems, both
above ground and underground and sets out the necessary personal protective measures
against hazards experienced by operators of such plant.
The changes included in this Standard cover the general safety requirements for large and
small conveyors and conveyor systems, and in particular the details for conveyor control
and motor drive isolation. Technical and editorial amendments have been incorporated in
line with available ISO documentation for mechanical handling equipment.
Major changes made in this edition include
(a)
clarification that the Standard is applicable to both above ground and underground
conveyor systems;
(b)
adding a Section dealing with requirements for specific applications, notably

underground coal mines; and
(c)
adding, as an appendix, ergonomic data.
The term normative has been used in this Standard to define the application of the
appendix to which they apply. A normative appendix is an integral Part of a Standard.
AS 17552000
CONTENTS
Page
SECTION 1 SCOPE AND GENERAL
1.1 SCOPE .........................................................................................................................5
1.2 OBJECTIVE ................................................................................................................5
1.3 APPLICATION............................................................................................................5
1.4 SECTION REQUIREMENTS......................................................................................6
1.5 REFERENCED DOCUMENTS ...................................................................................6
1.6 DEFINITIONS .............................................................................................................6
SECTION 2 REQUIREMENTS FOR DESIGN AND CONSTRUCTION
2.1 GENERAL ...................................................................................................................9
2.2 DESIGN AND CONSTRUCTION...............................................................................9
2.3 ACCESS TO CONVEYORS......................................................................................12
2.4 OPERATING CLEARANCE .....................................................................................12
2.5 LIGHTING.................................................................................................................12
2.6 ELECTRICAL REQUIREMENTS ............................................................................12
2.7 CONVEYOR CONTROL AND ISOLATION FACILITIES......................................13
2.8 FIRE PROTECTION..................................................................................................19
2.9 MARKINGS, SIGNS AND IDENTIFICATION........................................................19
SECTION 3 REQUIREMENTS FOR GUARDING

3.1 GENERAL .................................................................................................................21
3.2 DESIGN AND CONSTRUCTION OF GUARDS......................................................21
3.3 PARTS REQUIRING GUARDING ...........................................................................29
3.4 REMOVAL OF GUARDS .........................................................................................31
SECTION 4 REQUIREMENTS FOR SPECIFIC LOCATIONS
4.1 GENERAL .................................................................................................................32
4.2 TUNNELS, GALLERIES OR PITS ...........................................................................32
4.3 CONFINED SPACES ................................................................................................33
4.4 HAZARDOUS AREA................................................................................................33
4.5 CONVEYORS FOR MINING....................................................................................33
4.6 UNDERGROUND COAL MINES.............................................................................33
SECTION 5 REQUIREMENTS FOR SPECIFIC CONVEYOR TYPES
5.1 GENERAL .................................................................................................................37
5.2 SLAT CONVEYORS.................................................................................................37
5.3 TOWING CONVEYORS...........................................................................................37
5.4 ROLLER FLIGHT CONVEYORS.............................................................................37
5.5 OVERHEAD CHAIN OR CABLE CONVEYORS (POWER AND FREE TYPE) ....37
5.6 SWING TRAY CONVEYORS ..................................................................................38
5.7 VERTICAL CHAIN CONVEYOR (OPPOSED SHELF TYPE)................................38
5.8 BELT CONVEYORS GUARDING OF NIP POINTS ...............................................38
5.9 TRAVELLING TRIPPERS AND SHUTTLE CONVEYORS....................................40
5.10 SCREW CONVEYORS .............................................................................................40
5.11 DRAG CHAIN CONVEYORS ..................................................................................40
5.12 MOBILE AND TRANSPORTABLE CONVEYORS.................................................41
AS 17552000
Page
SECTION 6 SAFEWORK PRACTICES
6.1 GENERAL .................................................................................................................46
6.2 INFORMATION TO BE SUPPLIED AND MAINTAINED......................................46
6.3 SAFEWORK PROCEDURES....................................................................................47
6.4 TRAINING ................................................................................................................49
APPENDICES
A
GLOSSARY OF CONVEYOR TERMS ....................................................................50
B
REFERENCED DOCUMENTS .................................................................................78
C
ERGONOMIC DATA................................................................................................79
AS 17552000
STANDARDS AUSTRALIA
Australian Standard
ConveyorsSafety requirements
S E CT I ON
S COP E
AND
GE NE RAL
1.1 SCOPE
This Standard sets out the minimum safety requirements for the design, installation and
guarding of conveyors and conveyor systems. It includes requirements for users and
providers of inspection, maintenance, training and implementation of safe work practices
for such equipment. Particular emphasis is given to operational safety and the protection
afforded to operators, maintenance personnel or other persons who may be exposed to risks
to health and safety associated with conveyors or conveyor systems.
This Standard includes requirements for
(a)
specific locations such as hazardous areas, confined spaces and coal mines; and
(b)
specific types such as belt conveyors and mobile or transportable conveyors.
The Standard is not intended to apply to platform elevators, moving stairways or conveyors
specifically designed for the conveyance of people.
A glossary of conveyor terms in provided in Appendix A.
1.2 OBJECTIVE
The objective of this Standard is to enable designers, manufacturers, suppliers, employers
and users of conveyors and conveyor systems to minimize the risks to health and safety
where conveyors are used.
1.3 APPLICATION
The requirements of this Standard are intended to be used by designers, manufacturers,

suppliers, installers, users and owners of conveyors or conveyor systems.
The requirements of this Standard shall apply to all conveyors or conveyor systems
installed or reinstalled following the publication date of this Standard. This provision need
not apply where a contract for the supply and installation of a conveyor or conveyor system
has been entered into prior to that time.
Where a risk assessment is required by this Standard, the requirements of AS 4024.1,
AS/NZS 3931 and AS/NZS 4360 or equivalent Standards shall be followed.
Alternative methods of providing safety based on risk assessment in accordance with
AS 4024.1, AS/NZS 3931 and AS/NZS 4360 may be used provided that the level of safety
offered by the alternatives is at least equivalent to that provided by the methods given in
this Standard.
In addition to the requirements of this Standard, there may be other requirements set by the
regulatory authority. Users of this Standard should therefore make themselves aware of any
specific requirements in the jurisdiction where the conveyor or conveyor system will be
used.
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Standards Australia
AS 17552000
1.4 SECTION REQUIREMENTS

Conveyors and conveyor systems shall comply with the requirements provided for in each
relevant section of this Standard.
1.5 REFERENCED DOCUMENTS
A list of the documents referred to in this Standard is given in Appendix B.
1.6 DEFINITIONS
For the purpose of this Standard the definitions below apply.
1.6.1 Competent person
A person who has, through a combination of training, education and experience, acquired
knowledge and skills enabling that person to perform correctly a specified task.
1.6.2 Control circuit isolation
The interruption of the control circuitry of the drive motor(s) of a conveyor system(s).
1.6.3 Conveyor
Apparatus or equipment operated by any power other than manual, by which loads are
raised, lowered or transported or are capable of being raised, lowered, transported or
continuously driven by
(a)
an endless belt, rope or chain or other similar means;
(b)
buckets, trays or other containers or fittings moved by an endless belt, rope, chain or
other similar means;
(c)
a rotating screw;
(d)
a vibrating or walking beam; or
(e)
rollers
It includes the supporting structure and auxiliary equipment used in connection with the
conveyor.
1.6.4 Conveyor system
An installation comprising one conveyor, or multiple conveyors whose control is integrated.
1.6.5 Danger zone

Any zone in or around a conveyor or conveyor system in which a person is subject to a risk
to health or safety.
1.6.6 Emergency stop
A manual or automatically operated system designed to stop a conveyor system in the
shortest practicable time in an emergency.
1.6.7 Energy-isolating device
Any device that physically prevents the transmission or release of energy. These may
include, but are not limited to, electrical isolators, disconnect switches, line valves and
blocks.
1.6.8 Fail safe
The principle of failure to safety, which is any failure of the machinery, its associated
safeguards, control circuits or its power supply that leaves the machinery in a safe
condition.
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1.6.9 Fixed guarding

Guarding which can only be removed by the use of tools.
1.6.10 Guarded
Shielded, fenced, enclosed or otherwise protected by means of suitable enclosures, covers,
casing, shield guards, trough guards or railing guards which removes foreseeable risk of
personal injury being caused by accidental contact or approach, and for an under guard,
removes any additional foreseeable risk of personal injury caused by contact with, or
spillage of, material from the conveyor.
1.6.11 Guarded by location or position
Moving parts which are protected by their remoteness from the floor, platform, walkway or
other working level or which by their location with reference to frame, foundation, or
structure remove the foreseeable risk of accidental contact by people or objects.
1.6.12 Mining
A system of obtaining and processing minerals or coal, including quarrying.
NOTE: Where the general provisions of this Standard have been varied for mining applications
the following has been assumed:
(a)
Access to all conveyors by the general public is effectively controlled.
(b)
Access to all conveyors is limited to persons trained in the hazards that may be associated
with the conveyors.
1.6.13 Mobile conveyor

A conveyor whose location may be moved during its operation (see Figure 3.3).
1.6.14 Nip point
That point at which a moving conveyor element meets a fixed or moving element so that it
is possible to nip, pinch, squeeze or entrap parts of the human body coming into contact
with one of the two elements.
1.6.15 Normal stop
A manual or automatically operated system designed to stop the conveyor under normal
operating conditions.
1.6.16 Protective stop control
A stop control provided for the protection of the conveyor or personnel from a hazard
which, when activated, stops the conveyor and includes emergency stop controls.
1.6.17 Pull wire
A wire connected to a device, normally provided for emergency stop control which, when
pulled, activates the device.
1.6.18 Regulatory authority
A Minister of the Crown, a government department or other public authority having power
to issue regulations, orders or other instructions having the force of law in respect of any
subject covered by this Standard.
1.6.19 Runaway
Uncontrolled movement of the conveyor in either direction.
1.6.20 Sequence
A control system designed to stop or start a conveyor, depending upon the state of other
equipment.
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1.6.21 Shall
Indicates that a statement is mandatory.
1.6.22 Shear point
The point at which, or the line along which, a moving part meets or passes close enough to
a stationary part or object so that parts of the human body can be caught, trapped or pinched
between them.
1.6.23 Should
Indicates a recommendation.
1.6.24 Start
A manual or automatically operated control system designed to start the conveyor under
normal operating conditions.
1.6.25 Transportable conveyor
A conveyor which is not a mobile conveyor that can be moved as a unit from one location
to another.
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AS 17552000
S E CT I ON
RE QUI RE ME NT S FOR
AND CONS T RUCT I ON
DE S IGN
2.1 GENERAL
In addition to the requirements of this Standard, conveyors and conveyor systems shall be
designed and constructed consistent with the relevant requirements of AS 4024.1 and other
relevant Standards.
Safety features necessary for the safe operation of the conveyors and conveyor systems
shall be included at the design stage.
2.2 DESIGN AND CONSTRUCTION
2.2.1 Selection of materials
All materials used in the manufacture of conveyors shall comply with the relevant
Australian Standards. In the absence of an Australian Standard, appropriate International or
overseas Standards may be used.
2.2.2 Design requirements
The design and construction of a conveyor shall take into full account the magnitude,
incidence, conditions and manner of all loading and forces likely to be applied to the
conveyor.
The slope and characteristics of the conveying system shall be designed to prevent
hazardous unintentional sliding of the conveyed material under operating conditions.
2.2.3 Stopping devices
2.2.3.1 Safe stopping
Conveyors shall be designed to ensure that they will stop in the shortest practicable time
consistent with safety when the driving energy is disconnected, and remain stopped until
the energy is restored.
2.2.3.2 Anti-runaway device

Any conveyor which can run away due to the effect of gravity shall be provided with
device(s) which will automatically prevent run away. Where a belt, chain drive, fluid
coupling or similar device is interposed between the motor and the driven shaft, the antirunaway device shall be installed to prevent runaway in the event of a failure of the
interposing device. More than one anti-runaway device may be required on a chain
conveyor.
Where a hazard to people exists from the failure of an anti-runaway device then two
automatically operated devices shall be provided to prevent run away. Each device shall be
capable of holding the load independently. These devices should be monitored for wear and
effective operation.
Each anti-runaway device shall be rated to stop and hold at least 150% of the maximum
load applied by the conveyor.
NOTE: These devices include but are not limited to brakes, anti-runback or holdbacks.
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2.2.3.3 Prevention of hazardous movement

Where an electromechanical brake is provided on a conveyor which may run away or run
back, and a non-direct drive is used, e.g. a fluid coupling, brakes shall not be released until
the torque has been applied to the main driving shaft of the conveyor. They shall be applied
automatically if the power fails or the operating control is returned to the off or stopped
position. See also AS 4024.1.
2.2.3.4 Controlled speed of descent
Brakes which are manually released and applied by the movement of operating devices
shall be designed so that if the power is interrupted with the brakes in the release position,
the load can descend only at a controlled speed.
2.2.4 Lubrication points
Where bearings or other parts are inaccessible or are in a danger zone and require
lubrication, the lubrication point should be located in a position which is both accessible
and outside the danger zone. The lubrication points should be located outside the alignment
of the carrying mechanism of the conveyor and should be accessible without the removal of
any guard.
2.2.5 Take-ups and counterweights
2.2.5.1 Take-ups
All components of a take-up which can move during operation shall be guarded.
Where a take-up device can operate automatically, fixed distance guarding should be
provided to prevent access to all components of the tension carriage or balance weight.
Where there is access at the bottom of the gravity take-up, protection shall be provided to
eliminate the hazard from descent of the weight due to failure of a component. Provision for
the removal or disposal of spillage in this area shall be provided.
Suitably worded signs warning of the stored energy hazard of the take-up system, shall be
visible at each point of access to the take-up system and rope system. Such signs should
comply with the requirements of AS 1319.
2.2.5.2 Access to take-up
Means of access to the take-up for repair and maintenance purposes, together with provision
for releasing or securing the stored energy shall be incorporated in the design of the system.
2.2.5.3 Control of take-up
The manual control for the take-up shall be accessible from outside the guarded area.
Where automatic control of the take-up is provided, then isolation of the automatic
operation and selection of a manual operation should be provided.
Manually operated tension devices shall not be capable of free wheeling under any
condition.
Where take-ups are remote or on a different level from the main drive, an emergency stop
facility complying with Clause 2.7.7 shall be provided at the take-up.
2.2.5.4 Wire ropes for take-ups and counterweights
All wire ropes used for take-ups and counterweights of conveyors shall have a minimum
safety factor of 4.5, relevant to the maximum static load that can be applied by the tension
system. The minimum dynamic factor of safety should be 2.25.
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AS 17552000
2.2.6 Hinged section

2.2.6.1 General
Hinged sections of a conveyor or conveyor system used for the purpose of creating a
passageway shall be designed so that when the hinged section is opened while the conveyor
is in operation, it need only stop the adjacent upstream conveyor. The conveyor may be
restarted automatically upon closure of the hinged section provided that compliance with
the requirements of Clause 2.7.8.2 is assured.
2.2.6.2 Manually operated
Manually operated hinged sections shall be self-locking in the open position or
counterbalanced and shall be designed so that the maximum effort required to open or close
the hinged section does not exceed 150 N.
2.2.6.3 Power operated
Power-operated hinged sections shall be provided with mechanical safety devices which
restrict their closing to a safe speed and prevent them from falling in the event of a power
failure.
2.2.7 Raising and lowering systems
Conveyors which include an articulated or mobile part which is raised and lowered, shall be
fitted with devices for automatically immobilizing these parts in the event of loss of power.
The raising or lowering system shall be designed to prevent accidental movement or
kickback when operated.
The system controls shall be located so their operation is clear of the underneath of the
conveyor.
Stops or limiting devices shall be provided to prevent movement of the articulated or
mobile part beyond its designed limits.
2.2.8 Dust generation and control
Where dusts are present or may be generated due to the operation of a conveyor, measures
shall be taken to minimize the generation and control the presence of dust. The following
recommendations should apply:
(a)
Scrapers should be provided where material may be drawn into a pulley to the belting
contact area. The scraper should divert the material clear of the contact area.
(b)
Means should be provided at the discharge point of a conveyor to minimize carry

back of material.
(c)
For areas of a conveyor which may generate significant dust, (e.g. transfer points or
areas of high air velocity) means should be provided to collect or suppress the dust.
These means may include, but are not limited to, the following:
(d)
(i)
Water sprays.
(ii)
Dust cover hoods.
(iii)
Dust collections systems.
Horizontal areas on which dust can accumulate should be minimized.
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2.3 ACCESS TO CONVEYORS

2.3.1 General
Means of access to the conveyor and its controls for the purpose of working, operating,
inspecting or servicing shall be provided. Where fixed platforms, walkways, stairways or
ladders are used for providing access, they shall comply with the requirements of AS 1657.
Operation of the conveyor shall be from floors or platforms, not from stairways or ladders.
Regular work or servicing should not be undertaken from ladders.
In the design of access provided for the operation and maintenance of the conveyor or
conveyor system, alternative means of exit shall be provided for personnel in the case of
fire.
2.3.2 Crossovers for aisles and passageways
Where access to either side of the conveyor is required, crossovers or underpasses shall be
provided at appropriate intervals including at the head and tail end, at the drive and other
transfer points along the conveyor.
Where a conveyor crosses a walkway, aisle or passageway and the lowest part of the
conveyor or material or attachment is less than 2.1 m above the floor or walkway surface, a
crossover or underpass as appropriate shall be provided.
NOTE: For underground mining applications, the underpass may be a crawlway.
2.3.3 Working clearance

Where access is required along an operating conveyor, a minimum working clearance of
600 mm coupled with a minimum headroom of 2.1 m shall be provided down one side of
the conveyor. The non-walk side of the conveyor should have sufficient clearance to allow
any spillage of material to fall clear of the conveyor. Adequate clearance shall be provided
between the material being conveyed and the roof.
The provision for a minimum headroom of 2.1 m need not apply to underground mines.
2.4 OPERATING CLEARANCE
Adequate clearance shall be provided to prevent inadvertent contact between the conveyed
material and any part of the conveyor system, including installed equipment or structures.
Where it is possible to manually overload a conveyor to a point where adequate load
clearance is not maintained, a load gauge should be installed at the loading points.
2.5 LIGHTING
2.5.1 General
Suitable permanent or mobile lighting shall be provided for conveyors or conveyor systems
appropriate to their location in accordance with AS 1680.2.1.
For underground mining, a cap lamp or other portable light is acceptable for locations other
than transfers and drive heads.
2.5.2 Emergency lighting
Emergency lighting should be provided to allow for safe egress.
2.6 ELECTRICAL REQUIREMENTS
The electrical installation, components and associated equipment of conveyors or conveyor
systems shall comply with AS/NZS 3000 and other relevant standards appropriate to the
specific location or type of conveyor as provided for in this Standard.
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2.7 CONVEYOR CONTROL AND ISOLATION FACILITIES

2.7.1 General
Control and isolation facilities required in this Standard for conveyors and conveyor
systems shall be adequately rated.
2.7.2 System integrity
Design errors which compromise the intended integrity of a system can occur during any
phase of the design process (see Figure 2.1).
The system shall be designed in a manner that will reduce the possibility of errors being
introduced. It should be checked during all phases to confirm freedom from error. The
higher the level of integrity required and the more complex the system, the greater will be
the extent of the check. This applies both to systems where the logic is entirely determined
by permanent connections, e.g. a hard-wired electrical relay logic system, and to software
or other programmable systems. However, the increasing complexity of typical
programmable electronic systems highlights the difficulties faced by the designer who
needs to assure system integrity.
Programmable systems shall provide a level of performance at least equal to that afforded
by conventional hard-wired safety systems
FIGURE 2.1 PHASES IN THE DESIGN PROCESS
2.7.3 Main isolating device

An energy isolating device shall be installed to completely isolate the sources of drive
energy from the conveyor or conveyor system. This device shall be capable of being locked
in the isolating position, be of the manual reset type and be suitable for direct manual
operation. The main isolating device shall not be capable of being locked in the on
position. Suitable facilities shall be provided to clearly indicate the operated state of the
device.
2.7.4 Remote isolating device
Where it is required to isolate the conveyor remotely, an energy isolating device
conforming with the following shall be provided for this purpose:
(a)
The device shall be lockable in the isolated position and be of the manual reset type.
(b)
The device shall isolate the source of energy from the drive system by either
(i)
direct isolation of the energy source, or
(ii)
indirect isolation of the energy source via a control system.
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(c)
(d)
14
Where indirect isolation of the energy source via a control system is used, the
following shall apply:
(i)
The remote isolating device shall cause the isolation of the drive energy from
the conveyor via at least two independent means to assure system integrity.
(ii)
A system shall be provided to indicate at the remote isolation device, that the
drive energy has been isolated.
A prestart warning in accordance with Clause 2.7.5 shall be provided.
2.7.5 Prestart warning systems

Where an otherwise uncontrolled hazard may arise when a conveyor or conveyor system
starts, an automatically operated prestart warning system shall alert people to the fact that
the conveyor is commencing operation and a potential danger exists. The system shall be in
the form of an appropriately timed visual or audible warning given prior to the conveyor
starting.
Where auditory or visual warnings are provided they shall not be a substitute for physical
safeguards. Auditory or visual warnings shall be duplicated or overlapping and shall be
monitored or inspected periodically to ensure adequate levels of safety.
2.7.6 Protective stop control
The output from a protective stop control shall cause the conveyor to stop by the operation
of the energy isolating device. Activation of such control shall be by one of the following
methods:
(a)
Direct operation.
(b)
A non-reprogrammable interposing device (e.g. relays, including electronic relays).
(c)
A programmable interposing device for other than emergency stop controls.
The defeat of protective devices which may endanger personnel shall not be permitted.
Facilities should be provided for testing the operation of protective stop controls.
NOTES:
1 Where appropriate, warning of the impending operation, status and record of operation of
protective devices should be included in the design of the conveyor or conveyor system, e.g.
belt tracking.
2 Blocked chute, bin full and transfer overfull are typical of the stop facilities provided for the
purpose.
3 For mining applications see Clause 4.6.8.
4 Programming requires a change in function, operational logic or purpose. A change of address
or identification does not constitute reprogramming.
2.7.7 Emergency stop controls

Controls shall be provided to stop the conveyor or conveyor system in an emergency. These
stop controls shall be of the manually operated, automatic lock-off manual reset type. The
circuit in which emergency stopping controls are provided shall be designed fail safe and
otherwise protected from faults that may defeat the operation of the facility.
Emergency stop controls shall be capable of being operated with minimal effort without
danger to the operator and shall be provided where the operating control is clearly visible
and readily accessible even for inaccessible conveyors.
Emergency stop controls shall be provided as follows:
(a)
For conveyors not greater than 2.5 m in length and located less than 2.5 m above the
floor, walkway or platform, a single stop control at the middle of the conveyor.
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(b)
For conveyors greater than 2.5 m in length and located less than 2.5 m above the
floor, walkway or platform, at the head, tail, drive and at intervals not exceeding
30 m along the length of the conveyor.
(c)
For conveyors positioned more than 2.5 m from the floor, walkways or platforms, at
accessible locations at intervals not exceeding 100 m along the length of the
conveyor.
(d)
At positions adjacent to the conveyor at which the conveyor can be started.
(e)
At every permanent working station.
Provision of a pull wire activated device is considered adequate for the purposes described
above.
2.7.8 Stop/Start controls
2.7.8.1 General
Except for conveyors at mines, resetting of any normal stop control or emergency stop
control shall not restart the conveyor without the actuation of a start control
(see Clause 4.5.2).
Where practical, all stop/start controls and emergency stop facilities should be uniform
throughout the conveyor or conveyor system.
Where an otherwise uncontrolled hazard could exist at a loading, unloading or transfer
point in a conveyor system, the conveyor system shall be designed to operate in sequence
and be provided with automatic stop controls which are designed to prevent the hazard from
arising.
2.7.8.2 Automatic stop controls
Automatic stop controls provided for conveyor systems for other than safety purposes, e.g.
overdimensional load, tension mechanism overtravel, and temperature limit controls, should
not prevent the restarting of the system after resetting, provided that
(a)
the stopping device is labelled to indicate that the conveyor will restart upon resetting
the device; and
(b)
where this control is in a position from which the whole of the system cannot be
viewed and there is a possibility of accidents arising from the starting of the
conveyor, a warning signal in accordance with Clause 2.7.5 shall be provided.
NOTE: This stop control may be wired into electronic control equipment.
2.7.9 Pull wire requirements

2.7.9.1 General
Pull wires shall not be used as substitutes for guards. Where used as an emergency stop
control a pull wire activated device shall comply with following requirements:
(a)
Breaking, slackening or removal of the pull wire shall activate the device.
(b)
Where electrical continuity is monitored in the pull wire

(i)
the slackening requirement of Item (a) need not apply; and
(ii)
the conveyor shall stop in the event of the pull wire being broken or removed.
(c)
The force required to operate the pull wire activated device shall not exceed 70 N
when applied midway between supports and at right angles to the axis of a pull wire
with less than 300 mm movement and 230 N along the axis of the wire.
(d)
The design and distance between pull wire supports shall be such that the wire moves
freely when pulled and does not become disengaged from the support.
NOTE: A maximum spacing of 6 m should apply.
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Materials used for pull wires shall be of adequate strength, be protected against
environmental conditions and be suitable for handling without the need for additional
protection being worn by operators.
NOTE: Where more than one switch is used in a pull wire system, a visual indicator should be
provided to indicate which switch has been activated.
(f)
The switch shall be activated when the pull wire is pulled in any direction.
(See Figure 2.2).
Where an electric pull wire is used, it shall be installed as shown in Figure 2.2(c).
2.7.9.2 Location of pull wires
Pull wires should be located in such a manner that they are
(a)
clearly visible;
(b)
readily accessible from all areas of access to the conveyor;
(c)
located external to the vertical line of any nip or shear point and no further than 1 m
from the nip or shear points;
(d)
at least 900 mm above the access floor;
(e)
generally not more than 1500 mm above the access floor;
(f)
where all nip or shear points are greater than 1500 mm above the access floor the pull
wire requirement of Item (e) may be raised provided the pull wire is lower than all
nip or shear points; and
(g)
where it is possible for a person to be inadvertently on a moving conveyor, an

emergency stop should be provided and be located no closer to the conveyor
discharge than the maximum stopping distance of the conveyor. The emergency stop
should be accessible from the conveyor.
See Figure 2.3 for the preferred location of pull wires.
NOTES:
1 The requirements of Clause 2.7.9 relating to pull wires may be replaced by an alternative
emergency stop system providing an equivalent level of safety.
2 Pull wires are not an alternative to guarding.
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FIGURE 2.2 EMERGENCY STOP PULL WIREOPERATING DIRECTION

REQUIREMENTS
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DIMENSIONS IN MILLIMETRES
FIGURE 2.3 LOCATION OF PULL WIRES
2.7.10 Protection of controls

Where any hazard may exist due to inadvertent or unauthorized operation of any control,
then facilities shall be incorporated in the design of the controls to prevent such operation.
Typical facilities provided for this purpose include covers over controls, locked enclosures
and key operated switches.
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AS 17552000
2.7.11 Protection from overload

Overloading of a conveyor or conveyor system shall be prevented by provision of suitable
energy limiting devices. These devices include but are not limited to
(a)
electrical overload limiters;
(b)
fluid couplings;
(c)
shear pins; and
(d)
pressure relief valves.
Where a shear pin is used, a description of the size and type of material of the shear pin
shall be placed at an appropriate point on the conveyor to facilitate proper replacement.
All fluid couplings shall be protected from overpressure and over-temperature.
2.8 FIRE PROTECTION
2.8.1 Firefighting facilities
Where a fire hazard exists on a conveyor or conveyor system, firefighting facilities
appropriate to the risk shall be provided.
2.8.2 Fire risk
Where the operation of a conveyor or conveyor system could create a fire hazard, the design
of the conveyor or conveyor system shall include items to minimize the risk.
2.8.3 Fire detection
Where a hazard may be created by not detecting a fire on a conveyor or conveyor system,
fire detection facilities should be incorporated in the design.
2.8.4 Lubricants
Oils and lubricants should be effectively contained.
Accumulated spilled oils and lubricants should be controlled sufficiently to minimize any
potential fire hazards.
2.8.5 Accumulation of combustible materials
The accumulation of combustible material resulting from the operations of a conveyor shall
be controlled to prevent contact with the moving parts of the conveyor. This may be
achieved by the installation of easily maintained scrapers, loading point skirting, shedder
plates and self-shedding covers over components located beneath the conveyor.
In addition, sufficient space shall be provided under moving parts for the removal of
accumulated material. Generally, for bulk materials handling belt conveyors, not less than
300 mm should be provided for this purpose but, in no case shall this clearance be less than
150 mm.
2.9 MARKINGS, SIGNS AND IDENTIFICATION
2.9.1 General
Where appropriate, permanent markings, signs and identification plates shall be in
accordance with AS 1318 and AS 1319. Where a hazard could exist from the
misinterpretation of a symbol the meaning of the symbol shall be clarified in writing.
Markings, signs and labels shall be of durable corrosion resistant construction and be
permanently attached. Markings, signs and labels shall be installed or positioned so that
they are clearly visible and do not become obscured while in service.
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2.9.2 Information plates

Where appropriate, each conveyor should be provided with an information plate located at
the drive and detailing the following:
(a)
The manufacturers and supplierss name, trade name or mark.
(b)
An identification number.
(c)
Year of manufacture.
2.9.3 Safe working load

The safe working load of a unit handling conveyor should be exhibited at each loading
point. For overhead chain type conveyors the safe working load shall be indicated as mass
per attachments and total mass per structure.
The load capacity of bulk handling conveyors should be exhibited on the conveyor.
2.9.4 Marking of control devices
Each manually operated stop, start or other function control shall be identified with
markings, signs or labels in writing clearly indicating the purpose of the control. Not
withstanding the generality of this requirement, the following shall also apply:
Emergency stop devices shall be indicated by a sign.
(b)
Actuators of knock-off emergency stop devices shall be coloured red.
(c)
Signs shall be provided at each end and every 30 m along a conveyor where a pull
wire is used e.g. emergency stop.
(d)
Signs shall be provided at the isolating devices provided for in Clauses 2.7.3 and
2.7.4 which clearly indicate the function and purpose of the device. See Clause 6.3.3
for specific requirements for remote isolating devices.
(a)
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GUARDI NG
3.1 GENERAL
Guards shall be designed and provided to prevent access to danger zones unless the danger
zone is guarded by location or position. Guards shall be included in the design of the
conveyor or conveyor system and shall not in themselves create a hazard.
Particular attention is drawn to the mass of guards which may need to be manually lifted
into place. Guidance on manual handling is provided in NOHSC:1001 (1990).
All guards shall be secured in position so that they cannot be removed without the use of
tools unless an interlocking device is provided to automatically stop the conveyor in the
event of the removal of the guard.
For mining applications complying with Clause 4.5, guards may be of the lift-off design not
incorporating the interlocking device.
Guards should be designed so that it is not necessary to remove them for servicing or
inspection purposes.
NOTE: For example, interlocking may be achieved by a pull wire operated stop switch in
accordance with Clause 2.7.9, which operates automatically when the guards are removed.
3.2 DESIGN AND CONSTRUCTION OF GUARDS

3.2.1 General
Unless otherwise specified guards shall be designed and located in accordance with the
requirements of AS 4024.1. Guards shall be designed to prevent
(a)
persons reaching into the danger zone;
(b)
clothes and hair or other body parts becoming caught;
(c)
conveyed materials accidentally falling or being projected onto persons;
(d)
the hazard from the failure of a component;
(e)
inadvertent contact with a danger point on the conveyor; or
(f)
inadvertent contact with hot or hazardous fluids from fluid couplings or torque
converters.
3.2.2 Materials
Guards shall be made of solid material, mesh or equivalent construction. Sheet metal guards
should not be less than 1.5 mm thick. Mesh guards should not be less than 1.5 mm wire
gauge, or 3 mm wire gauge for 50 mm square mesh and above.
3.2.3 Strength
The safety distances specified in Clause 3.2.4 shall be maintained when loads are applied as
follows:
(a)
A force of 450 N at a point on the guard applied over a square area of 50 mm

50 mm.
(b)
For guards which can be climbed or rested upon, a mass of 90 kg placed on the guard
and a simultaneous horizontal force of 220 N applied to points selected to establish
the strength of the guard. The required clearances from the danger zone shall be
maintained when a force of 450 N is applied at point on a guard over a square area of
50 mm 50 mm.
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3.2.4 Reach dimensions and guard placement

Except where stated elsewhere the design and construction of guards and their subsequent
location shall be such that the safety distance from any nip point or shear point to the
nearest point of access is in accordance with Appendix C.
Typically the safety distances are as follows:
(a)
For square mesh with opening size up to and including 9 mm, guards shall be at least
25 mm from the nip or shear point.
(b)
For square mesh with opening above 10 mm and up to 50 mm, guards shall be at least
200 mm from the nip or shear point.
(c)
For fence type guards the maximum distance between the underside of the fence and
the floor shall be 200 mm. The location of the nip or shear point may reduce this
dimension.
3.2.5 Types of guards

3.2.5.1 General
Guards are normally provided in the form of
(a)
fixed enclosure guards see Figure 3.1;
(b)
fixed distance guards see Figure 3.2; or
(c)
nip guards where shear hazards are not present see Figure 3.3.
3.2.5.2 Fixed enclosure guard

A fixed enclosure guard is a guard which, when in position, prevents access to a hazard or
area by enclosure. It encloses the hazard to prevent access, so far as is practicable,
consistent with the passage of the conveyor, materials and spillage.
Where an opening exists for the passage of the conveyor, the guard at the opening should
extend for a minimum distance of 1000 mm from the hazard (see Figure 3.1). This distance
shall be increased to 1150 mm when the pulley diameter is greater than 1000 mm. Where
fixed enclosure guards cannot be used, fixed distance guards or nip guards shall be
installed.
Guarding of idler sets where required should be provided on the approach side and should
extend for 1000 mm from the nip point. On the out-running side the guard should extend for
at least 1000 mm beyond the nip point (see Figure 3.4).
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AS 17552000
FIGURE 3.1 FIXED ENCLOSURE GUARD
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3.2.5.3 Fixed distance guards

A fixed distance guard does not completely enclose a hazard but reduces access by virtue of
its physical dimensions and its distance from the hazard. It shall be designed and
constructed with the object of preventing any part of the body from reaching a hazard. It
may take the form of a fixed barrier of fence designed to such a height so as to prevent
normal access to the danger zone, although climbing over this type of safeguard cannot be
entirely eliminated. (See Figure 3.2.)
Where fence type guards are used they shall ensure that
(a)
the access to any fenced area includes a system to automatically stop the conveyor
before access is obtained to the danger zone; and
(b)
a sign shall be provided at every access point through the fenced off area stating
DANGERIsolate drive energy.
3.2.5.4 Nip guards

Nip guards shall extend for a minimum of 150 mm from the nip point and across the width
of the belt for the full length of the idler or pulley and shall be closely fitted to follow the
felt line and idler or pulley periphery approaching the nip, with gap not exceeding 4 mm.
See Figure 3.3(a) and 3.3(b).
NOTE: Nip guards may not provide adequate protection from injury due to entrapment of hair,
skin or clothes.
The principle of nip guards is shown in Figure 3.3(c). Examples of typical arrangements for
nip guards at tail pulleys are shown in Figures 3.3(e) and 3.3(f).
Where nip guards of alternative designs are used, which do not provide adequate protection,
they should be fitted in association with fixed enclosure guards or fixed distance guards.
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AS 17552000
FIGURE 3.2 (in part) FIXED DISTANCE GUARD
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AS 17552000
FIGURE 3.3 (in part) NIP GUARDS
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FIGURE 3.3 (in part) NIP GUARDS
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AS 17552000
3.3 PARTS REQUIRING GUARDING

3.3.1 Shear points and nip points
Shear points and nip points in locations less than 2.5 m above any access floor, platform
level, stored goods or materials shall comply with the following requirements:
(a)
All shear and nip points shall be guarded. Shear and nip points are created where the
gap between any moving part of the conveyor and any fixed equipment is greater than
4 mm and less that 120 mm.
(b)
As an alternative, pop-out rollers or dead plates which, when operating, allow a

minimum clearance of 120 mm to be maintained, may be provided. The force required
to operate such devices shall not exceed 110 N. (See Figure 3.5.)
(c)
Where the surface of the moving part of the conveyor is provided with projections
exceeding 6 mm in height, or where there is any type of attachment to the moving
part, the minimum clearance of 120 mm shall be maintained between the highest
point of the projection and the fixed equipment.
(d)
The requirements of this Clause need not apply to nip points associated with those
belt conveyor idlers which comply with the requirements of Clause 5.8.
FIGURE 3.4 IDLER SET GUARDSFIXED ENCLOSURE OR FIXED DISTANCE
3.3.2 Rotating parts

All exposed projections, gaps, shaft couplings or collars shall be guarded.
All fluid couplings fitted with a fusible plug or bursting discs shall be provided with
suitable guards to control and contain discharge of fluid in the event of the plug fusing.
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3.3.3 Hoppers and chutes

All openings to hoppers and chutes shall be suitably guarded where there is a risk of
contacting dangerous parts or of personnel falling into the opening. Hoppers or chutes shall
be provided with access or openings so that, as far as possible, any necessary cleaning or
inspection may be carried out from outside the hopper or chute.
The sides of open hoppers or chutes shall be high enough to prevent material falling into
working areas below. Open chutes should be provided with plates at the point where
conveyors discharge into them to prevent materials from bouncing out of the chute.
Chute doors shall be located so that when open they do not create a hazard to personnel
during normal operation of the plant.
Where a hazard exists from moving equipment behind inspection doors, the doors shall be
lockable, or interlocked to the conveyor controls.
3.3.4 Loading, unloading and discharge points
Wherever a person has access to a loading, unloading, work station, transfer, or discharge
point, guards in the form of guard-rails, fences, or close fitting guards shall be installed to
prevent injury to that person.
3.3.5 Guarding of openings in floors
In locations where conveyors pass through a floor or where it is possible to step on moving
parts of the conveyor or into the opening, guard railing and toeboards shall be provided in
accordance with AS 1657.
3.3.6 Falling materials
Where a hazard can be created by the material being conveyed falling into or being
projected into an accessible area, then guarding shall be provided. Consideration should be
given to the height, mass and speed of the material being conveyed. (See Figure 3.6.)
NOTE: The possibility of trapping at the junction of a powered conveyor and an idle roller conveyor can be
avoided by making the first idle roller free to move away along an incline A cut in the sides of the
conveyor. The angle of the incline is so arranged as to prevent lateral movement of the roller during the
passage of goods from the belt to the idle roller conveyor. Care should be taken to ensure that the weight
and dimensions of the loads being conveyed do not prevent the roller from lifting. In some installations
more than one free roller may be required. This solution is not effective where the rollers are powered.
FIGURE 3.5 POP-OUT ROLLER
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AS 17552000
FIGURE 3.6 GUARD TO PROTECT FROM FALLING MATERIAL
3.4 REMOVAL OF GUARDS

3.4.1 General
Where work requires the removal of guards, the conveyor shall be isolated in accordance
with Clause 6.3.2.
3.4.2 Inspection doors in fixed guards
Where required for inspection, maintenance, cleaning, or operational purposes, inspection
doors may be provided in a fixed guard. These openings shall not expose a person to the
hazard being guarded.
3.4.3 Removal of guards and opening of inspection doors
Lifting handles or lugs shall be provided for the safe removal of guards and opening of
inspection doors.
3.4.4 Labelling of guards
Removable guards shall be clearly labelled as follows, at intervals not greater than 10 m:
DANGERIsolate energy source before removing guard.
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4.1 GENERAL
The additional requirements below are relevant to the specific location in which the
conveyor is to be installed or used and shall be included in the design.
4.2 TUNNELS, GALLERIES OR PITS
4.2.1 Materials inflow
The entrance to a tunnel, gallery or pit shall be designed to prevent any inflow of water or
other materials.
4.2.2 Drainage facilities
Drainage facilities shall be provided in a tunnel, gallery or pit.
4.2.3 Depth indication
Where a risk exists of an accessible area in a tunnel, gallery or pit becoming flooded, an
appropriately located device providing visual indication as to the depth of any water or
other material in the area shall be provided.
4.2.4 Location of controls
Manual controls for any pumping systems shall be located outside any area which may
become flooded.
4.2.5 Ventilation
Tunnels, galleries and pits shall be adequately ventilated. Where ventilation is provided by
mechanical means, systems shall be incorporated in the design to manage any risk arising
from the failure of the ventilation.
4.2.6 Alternative egress
Where there is a risk of the normal access to a tunnel, gallery or pit becoming blocked, an
alternative means of egress shall be provided.
4.2.7 Openings to pits or sumps

Where there is a risk of falling into a temporary or permanent opening of a pit or sump, the
opening shall be guarded in accordance with AS 1657. Where it is not practical to have
fixed barriers or guardrails fitted to a temporary opening, then temporary barriers or
guardrails shall be provided.
4.2.8 Accumulated material
Pits shall have adequate space for the accumulation of spilled material and means for the
ready removal of such accumulation.
4.2.9 Additional requirements
4.2.9.1 General
A risk assessment shall be conducted which includes but is not limited to the provisions
contained in Clause 4.6 for the areas given in Clauses 4.2.9.2 to 4.2.9.5.
4.2.9.2 Tunnels, galleries or pits
All tunnels, galleries or pits which are enclosed to a major degree on all sides and which are
greater than 60 m in length;
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4.2.9.3 Confined spaces

All confined spaces as nominated in Clause 4.3;
4.2.9.4 Hazardous areas
All hazardous areas as nominated in Clause 4.4;
4.2.9.5 Underground mines
All underground mines including the areas nominated in Clause 4.2.9.2 require that
(a)
consideration shall be given to ensuring that sufficient space be provided to permit

transport of a stretcher patient along at least one side of the conveyor; and
(b)
at least two means of egress shall be provided.
4.3 CONFINED SPACES

Where a working area in or about a conveyor installation is considered as a confined space
as defined in AS 2865, the provisions of that Standard shall be applied to the installation.
4.4 HAZARDOUS AREA
Where the area in which a conveyor is to be installed or used is classified as a hazardous
area in accordance with AS 2430 (all Parts), the electrical equipment used in the hazardous
area shall be selected, installed and maintained in accordance with AS/NZS 2381.1.
4.5 CONVEYORS FOR MINING
4.5.1 Emergency stop
In addition to the requirements of Clause 2.7.7 a pull wire system shall be installed in
accordance with Clause 2.7.9 on every belt conveyor.
4.5.2 Restart
Resetting alone of any protection or stop control may restart the conveyor without the need
for separate actuation of a start control, provided that a prestart warning in accordance with
Clause 2.7.5 has been given.
4.5.3 Prestart warning
A prestart warning system in accordance with Clause 2.7.5 shall be installed on every
conveyor. This provision need not apply to conveyors controlled by a single operator who
can readily see the full length of the conveyor and has access to a manually operated
prestart warning system.
4.6 UNDERGROUND COAL MINES
4.6.1 Maximum surface temperature
In underground workings at a mine the surface temperature of any part of the conveyor or
conveyor system shall not exceed 150C under operating conditions.
4.6.2 Light metals
In underground workings in a mine, light metals shall not be used for the construction of
external surfaces of conveyor equipment. Light metals are aluminium, magnesium,
titanium, or an alloy containing an aggregate of more than 15% by mass of aluminium,
magnesium and titanium, or an alloy containing an aggregate of more than 6% by mass of
magnesium and titanium.
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4.6.3 Control of static electricity

4.6.3.1 Anti-static materials
In underground mines where explosive atmospheres may be present, conveyor belting and
non-metallic materials that may contact the conveyor belting shall be manufactured from
material that has anti-static properties. These items include but are not limited to, scraper
blades, ploughs, skirt rubber, pulley and idler lagging, skid bars and spliced joints.
Anti-static properties shall conform with the requirements of AS 1333 or AS 1332,
electrical resistance (Grades E and S belts). The electrical resistance shall be measured in
accordance with AS 1334.9.
4.6.3.2 Anti-static measures
Where a conveying system can introduce a risk arising from static electricity, for example
from pneumatic bulk transfer conveyors, they shall be provided with means of static
discharge. Guidance may be found in AS/NZS 1020.
4.6.4 Hazardous zone electrical equipment
Where a regulatory body or user establishes a hazardous zone or area in underground
working at a mine, the electrical equipment used in those areas shall comply with AS 2380
(all Parts).
4.6.5 Fire resistant materials
4.6.5.1 Non-metallic materials
Non-metallic materials used in the construction of conveyors, shall comply with the fireresistant requirements of Grade S belting, as defined in AS 1333 or AS 1332, as applicable,
for the following items:
(a)
All conveyor belting and spliced joints.
(b)
Items in contact with or in close proximity to the belt, e.g. pulley and idler lagging,
scraper blades, impact bars, skirting rubber.
(c)
Structural components.
(d)
Chutes and lining.
(e)
Guards/covers/hoods.
4.6.5.2 Fluids
Fluids used in fluid couplings and torque converters shall be fire resistant to AS 3997.2.
NOTES:
1
2
Guidance on the selection of fire-resistant hydraulic fluids may also be found in ISO 7745.
Phosphate ester based hydraulic fluids may not be suitable for some underground situation.
4.6.6 Bearing cage materials

Non-metallic bearing cages for anti-friction bearings should not be used.
4.6.7 Firefighting facilities
Provision for automatic fire suppression facilities should be considered at conveyor drive
locations and other areas where the risk of fire warrants this equipment. These are
additional to the requirements of Clause 2.8.
4.6.8 Protective stop controls
4.6.8.1 General
Protective stop controls shall be provided in accordance with Clauses 4.6.8.2 to 4.6.8.9. The
requirements are summarized in Table 4.1.
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TABLE 4.1
PROTECTIVE STOP CONTROLS
Parameter
Mandatory
Belt slip
Fluid coupling over-temperature
Brake over-temperature
Recommended
Brake release
Belt tracking
Fire detection
Bearing over-temperature
Blocked chute
4.6.8.2 Belt slip

A protective stop control shall be fitted to detect slippage between the drive pulleys and the
belt. When the slip exceeds 10% the conveyor shall stop. This device may be over-ridden
during start-up of the conveyor for a maximum period of 35 seconds.
4.6.8.3 Fluid couplings over temperature
Fluid coupling shall be fitted with an overtemperature device which operates before
(a)
the coupling surface reaches 150C; or
(b)
the fluid reaches the maximum operating temperature as recommended by the

manufacturer of the fluid, whichever is the lesser.
NOTE: Fluid couplings should be fitted with a high-temperature trip device and a high
temperature thermal plug (see Clause 3.3.2).
4.6.8.4 Brake overtemperature

Braking systems should have an over-temperature protective stop control arranged to stop
the conveyor.
4.6.8.5 Brake release
Mechanical brakes shall be fitted with a device designed to detect the released position of
the brake. The device shall be arranged to stop the conveyor in the event of the brake
failing to release when required.
4.6.8.6 Belt tracking
Devices shall be provided to detect and stop the conveyor in the event of excessive side
movement of the conveyor belt while operating. As a minimum, these devices shall be
installed within 30 m of either side of any transfer point, drive head, loop take-up or place
where a significant change in belt elevation occurs.
NOTE: A timer may be fitted to prevent nuisance trips of the conveyor which may occur due to
momentary tracking problems or to a small protrusion to the side of the belt. A self-resetting
override device may be provided for belt tracking purposes.
4.6.8.7 Fire detection

Devices should be installed to detect fire at conveyor drive locations and other areas where
the risks of fire warrant these devices.
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4.6.8.8 Bearing over-temperature

Where a hazard may result from the overheating of a pulley or gearbox bearing, devices
should be installed to detect the overheating. The detection system shall not be selfresetting. The system provided shall latch off and be of the manual reset type.
NOTE: Dead shaft bearing seizure may not necessarily be prevented by a bearing overtemperature monitoring device, hence, the use of a device which detects and stops inadvertent
shaft rotation may prevent a fire.
4.6.8.9 Blocked chute

Devices shall be installed to detect blockage of chutes incorporated in a conveyor or
conveyor systems.
4.6.9 Accumulation of combustible materials
In addition to the requirements of Clause 2.8.5, a space of not less than 300 mm shall be
provided below the lowest part of the lowest belt surface except that at the first loading end
of each conveyor system where the clearance shall be sufficient to prevent contact between
the belt surface or any rotating element and any spillage.
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5.1 GENERAL
The additional requirements below shall be included in the design and construction relevant
to the specific conveyor type detailed in this Section.
5.2 SLAT CONVEYORS
5.2.1 Slat load design
Slats shall be designed, to accommodate live loads. The design shall include an allowance
for wear.
5.2.2 Spacing between slats
The distance between slats when travelling in a straight line along a slat conveyor should be
25 mm, except that this gap may be increased in accordance with the safety distances given
in AS 4024.1, or where alternative forms of guarding are provided in accordance with
AS 4024.1.
5.3 TOWING CONVEYORS
5.3.1 Truck release mechanism
A device shall be provided to automatically release a towed truck from the towing chain of
a towing conveyor in the event of the truck or load becoming obstructed.
5.3.2 Clearances
There shall be at least 500 mm clearance between any towed truck, including its load, and
any other truck or fixed object.
5.3.3 Guarding of wheels
Tow truck wheels shall be guarded by one of the following methods:

(a)
By guards on the wheels to within 20 mm of the floor.
(b)
By a skirt guard on the truck to within 20 mm of the floor.
(c)
Any other means which provides equivalent protection for personnel.
5.4 ROLLER FLIGHT CONVEYORS

The distance between rollers of a roller flight conveyor shall not be greater than 25 mm
except that this gap may be increased where the entire space under the top of the carrying
rollers is a solid smooth bed eliminating any shear hazard or where shear and nip points are
guarded.
5.5 OVERHEAD CHAIN OR CABLE CONVEYORS (POWER AND FREE TYPE)
5.5.1 Guarding yokes
Where the underside of the free track of an overhead chain or cable conveyor is within
2.5 m of the floor level, the power chain and trolley shall be suitably guarded where they
pass through the yokes. Where, however, access to the trolley is from walkways provided
for maintenance, yokes need not be specifically guarded provided that the clearance
between the trolley bracket and the yoke is not less than 30 mm.
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5.5.2 Drop sections

Where drop sections are used, suitable means shall be provided to prevent the following
free trolley from entering the open section of track. and the free trolley in the drop section
shall be positively retained on the track.
Means shall be provided to stop the descent of any drop section or to control its speed to
not more than 125% of its normal operating speed; in any event its speed shall not exceed
500 mm/s.
5.6 SWING TRAY CONVEYORS
5.6.1 Fork tray type
Where there is more than one loading point in a fork tray conveyor, the conveyor or its
controls shall be designed to ensure that the trays cannot be at the loading points at the
same time. Loading and unloading points shall be guarded by fixed guards extending a
distance of at least 1000 mm from the sill line of the loading or unloading point.
5.6.2 Solid tray type
Where the loading or unloading of a solid tray type conveyor is not automatic, the loading
and unloading point shall be provided with doors interlocked to stop the conveyor when the
doors are open.
5.7 VERTICAL CHAIN CONVEYOR (OPPOSED SHELF TYPE)
On a vertical chain conveyor means shall be provided to stop the conveyor in the event of
any portion of the load projecting beyond the door head or sill line.
5.8 BELT CONVEYORS GUARDING OF NIP POINTS
On belt conveyors, unless guarded by position, the following nip points shall be guarded
(see Figure 5.1):
(a)
Drive pulleys.
(b)
Head and tail end pulleys.
(c)
Bend and snub pulleys.
(d)
Take-up pulleys.
(e)
Transition idlers adjacent to pulleys.
(f)
Carrying and return idlers at convex curves (brow position).
(g)
Carrying and return idlers beneath feed hoppers and skirt plates.
(h)
Carrying and return idlers at positions where the lift of the belt is restricted.
(i)
Idlers accessible from underpasses, crossovers and crawlways.

NOTE: There may be a nip point created in the opposing direction to the normal operation of the
conveyor by either of the following:
(a)
Reversing of the belt by design.
(b)
Reversing of the belt due to forces within the system, e.g. changes in the conveyor tension
system.
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FIGURE 5.1 BELT CONVEYOR NIP POINTGUARDING
39
AS 17552000
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5.9 TRAVELLING TRIPPERS AND SHUTTLE CONVEYORS

Where there is a risk of trapping a person, a working clearance of 500 mm shall be provided
between a moving tripper, shuttle conveyor or radial conveyor and other objects likely to
cause entrapment along the length of travel and at either end.
Guards shall be provided to prevent any trapping between the travelling wheels and the
rails. See Figure 5.2 for typical requirements.
Where access is provided to, or across a travelling tripper, guards shall be provided to
prevent any trapping between any fixed or moving object.
Where a crossover or underpass is attached to a travelling tripper a suitable boarding switch
should be provided.
For a manually positioned tripper, a travel-locking device shall be provided.
FIGURE 5.2 TYPICAL GUARDS FOR TRAVELLING TRIPPER
5.10 SCREW CONVEYORS

All casings, loading, delivery, drainage and inspection apertures or chutes of screw
conveyors shall be guarded or interlocked to prevent contact with the screw and nip point.
5.11 DRAG CHAIN CONVEYORS
Where inspection panels are used in the top of a trunking which encloses a drag chain, a
wire mesh screen shall be provided under the door or panel; such screens shall be designed
and constructed in accordance with the requirements of Clause 3.2.3.
The flights and chain of a drag chain conveyor shall be guarded where a hazard exists.
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AS 17552000
5.12 MOBILE AND TRANSPORTABLE CONVEYORS

5.12.1 General design and construction
Mobile and transportable conveyors shall be designed and constructed to remain stable
under the stated loads and operating conditions. The design and construction of mobile and
transportable conveyors shall take into account the magnitude, incidence, condition and
manner of loading, including possible overloads and all other forces likely to be allied to
the conveyor under the operating conditions.
5.12.2 Margin of stability
The margin of stability shall be determined for mobile and transportable conveyors under
the combined effects of
(a)
wind loading;
(b)
design live and dead loads;
(c)
design live load and dynamic effects; and
(d)
tilting due to terrain or flat tyre where applicable.
The margin of stability expressed as a percentage shall be calculated in accordance with the
following equation:
a
m = 100 1
b
where
m = margin of stability, in percent
a=
stabilizing moment about the axis of tipping of the conveyor due to the
worst case design loads, in newton metres
b=
overturning moment about the axis of tipping of the conveyor due to the
worst case design loads, in newton metres
The margin of stability for mobile or transportable conveyors shall not be less than 50%.
5.12.3 Pneumatic tyres
Where pneumatic-tyred wheels are used on a mobile or transportable conveyor, stability
shall be maintained in a condition of under-inflation or loss of air in one or more of the
tyres.
5.12.4 Boom mounting

The boom or trunking shall be mounted on the chassis, base or wheels. The plan distance at
right angles to the boom or trunking between the chassis, base, or wheels shall not be less
than 25% of the elevated height of the boom or trunking.
5.12.5 Locking against movement
Suitable locking devices or brakes shall be provided on transportable conveyors to prevent
unwanted movement while the conveyor is in use.
5.12.6 Attachment points for towing
Suitably designed points of attachment shall be provided for towing mobile and
transportable conveyors.
NOTE: Reference should be made to traffic rules for transporting or operating conveyors on
public roadways.
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5.12.7 Loss of power

Suitable means shall be provided to maintain the conveyor boom in any position when the
power is removed from the raising or lowering medium. A screw or helix type brake fulfils
this purpose. Ratchet and pawl type winches without brakes shall not be used.
5.12.8 Wire ropes
5.12.8.1 Safety factors and diameter ratios
Wire rope, where used for elevating booms, shall comply with the appropriate requirements
of AS 3569 and AS 2759 with respect to the minimum factor of safety and ratio of rope
diameter to drum and sheave diameter.
5.12.8.2 Attachment criteria
Attachment of the ropes shall be made in such a manner that will ensure the strength of the
rope is maintained in the connection.
5.12.8.3 Minimum diameter
Ropes of less than 6 mm diameter shall not be used.
5.12.8.4 Load equalization
Where more than one rope or fall is used, a means of equalizing the load on each rope shall
be provided.
5.12.8.5 Anchorage
Rope anchorages shall have a minimum safety factor of 4.5.
5.12.9 Boom or trunking
5.12.9.1 Minimum approach
The boom or trunking shall be designed so that it cannot approach closer than 2500 mm to
the ground or floor level, unless measures are taken to ensure that the elevated boom or
trunking has its descent controlled to a safe regulated speed. The boom raising frame shall
not become detached from the boom trunking or base.
5.12.9.2 Separation from drive
The boom or trunking shall be attached and supported so that, when it is at its most lowered
elevation or being transported, it cannot rest upon the conveyor drive.
5.12.9.3 Warning sign Overhead Power

A permanent sign warning of the hazard from overhead powerlines, shall be installed in a
conspicuous position at each towing point on a transportable conveyor and adjacent to the
driving controls of a mobile conveyor. This applies to mobile or transportable conveyors
which have any parts that can be raised in excess of 2000 mm. See Figure 5.3 for a typical
sign.
5.12.9.4 Safety distances from overhead power lines
The conveyor shall not approach any closer to overhead power lines than the following
(see Figure 5.4):
(a)
For distribution lines carrying up to 132 kV on poles
.................
(b)
For transmission lines carrying greater than 132 kV on towers
...........
3 m.
8 m.
5.12.9.5 Movement of transportable conveyors

Transportable conveyors shall be moved to another location only after the boom or trunking
has been lowered into its transportable position. A warning notice advising this requirement
shall be prominently displayed on the conveyor.
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FIGURE 5.3 TYPICAL WARNING SIGN FOR OVERHEAD POWER
5.12.10 Internal combustion engine drive
Where an internal combustion engine is used as the conveyor drive power, the following
shall apply:
(a)
The conveyor shall be fitted with overspeed protection designed to stop the drive in
the event of the maximum design speed being exceeded.
(b)
The conveyor shall be fitted with a fire extinguisher of suitable capacity and type to
extinguish a fire arising from the combustion of fuel.
(c)
The conveyor shall be fitted with a sign, in a conspicuous position, warning of the
hazard arising from the exhaust fumes of the engine. This warning shall include
particular reference against use of the conveyor in non-ventilated or confined spaces.
(d)
Due consideration should be given to the control of static electricity (see

AS/NZS 1020).
(e)
Where manual starting mechanisms are fitted to the motor, the design shall not create
a hazard to the operator.
NOTE: It is recommended that impulse, spring or permanently attached cord type starters be
provided for this purpose.
5.12.11 Electrical cables

Where electrical cables are subject to movement or vibration, such cables shall be of the
flexible type and be
(a)
protected to prevent damage; and
(b)
attached to the conveyor to prevent undue strain on the electrical connections or

cable.
Residual current devices should be provided to circuits feeding mobile conveyors.

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A sign shall be attached to the conveyor statingThis equipment should be connected only
to a power circuit equipped with residual current devices.
5.12.12 Tooth or dog clutches
Where used on a mobile or transportable conveyor tooth or dog type clutches shall have not
less than four teeth or dogs. Tooth or dog type clutches shall be designed and constructed to
prevent inadvertent disengagement.
5.12.13 Guarding
In addition to and in accordance with the requirements of Section 3, mobile and
transportable conveyors shall be fitted with guards on
return side idlers less than 2.5 m from any access floor or platform level or at any
other position that is not guarded by position or location;
(b)
flywheels, coupling and starter mechanisms of petrol engines;
(c)
exposed or extended shafts of crank type starting mechanisms;
(d)
bag and bale conveyors to prevent dislodgment of the load in the form of side guards
or aprons extending to an effective height of 100 mm;
(e)
exposed screws, chains or flights in hoppers designed to prevent contact with moving
parts;
(f)
return side chains with flights, typically by positioning the chain to prevent contact
by a person, enclosing in a duct or other similar barrier; and
(g)
power take off drives and shafts shall be guarded in accordance with AS 1121.
(a)
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AS 17552000
DIMENSIONS IN METRES
FIGURE 5.4 CLEARANCES FROM OVERHEAD POWER LINES
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S E CT I ON
S AFE WOR K
P R ACT I CE S
6.1 GENERAL
This Section deals with safework practices to be developed, implemented and maintained
by owners and users to ensure the safe installation, operation, maintenance and dismantling
of conveyors and conveyor systems.
The minimum requirements for safework practices are detailed in this Section. However,
the owner should also carry out appropriate risk assessments to establish the safework
practices for the activities associated with the conveyor or conveyor systems under the
owners control.
In addition, a comprehensive system of audits and checks shall be introduced to measure
the effectiveness of the safework practices. Where these practices are found to be deficient
the owner shall implement changes to correct the deficiency.
6.2 INFORMATION TO BE SUPPLIED AND MAINTAINED
6.2.1 General
Documentation shall be provided, used and maintained for the operation of the conveyor or
conveyor system provided for in this Standard. Documentation shall include but be not
limited to synopses of plant, installation, commissioning, dismantling, operating and
maintenance instructions. In each area where information is required, identification of
potential hazards and their control shall be included.
All information shall be presented in English (and other languages where necessary) and be
in a logical sequence with clear illustrations.
Where risk assessments are undertaken, documented evidence of such assessment shall be
recorded and maintained.
6.2.2 Synopsis of plant
The owner shall maintain information regarding the synopsis of plant supplied by the
manufacture and designer of the conveyor or system or system components.
The following information shall be included in the synopsis of plant:

(a)
Design capacities and criteria of the conveyor system and its components.
(b)
General arrangement drawings including identification of system components.
(c)
Schematic and logic drawings of power and control facilities.
(d)
Parts identification including reorder details.
(e)
Lubrication requirements.
6.2.3 Installation, commissioning and dismantling

The owner shall maintain information regarding the installation, commissioning and
dismantling of the conveyor or conveyor system including requirements of the manufacturer
and designer.
The following information shall be provided and maintained:
(a)
Installation procedures.
(b)
Dismantling, transport or removal procedure.
(c)
Pre-operational servicing procedures including lubrication requirements.
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(d)
Procedures for the adjustment and setting of controls.
(e)
Commissioning and testing procedures.
(f)
Records of data collected during commissioning.
(g)
A copy of each programmable logic controller program.
(h)
Transport weights and identification of lift points.
AS 17552000
6.2.4 Operating and maintenance instructions

The owner shall maintain information regarding the operation and maintenance of the
conveyor or conveyor system including requirements of the manufacturer and designer.
The following information shall be provided and maintained:
(a)
Loading and unloading instructions including ergonomic requirement.
(b)
Maintenance instructions and schedules which include lubrication testing, inspection

and repair procedures.
(c)
Operating instructions which incorporate clear instructions for the operation of the
conveyor system from start up to shut down including all possible sequences of
control.
(d)
Emergency procedures.
6.3 SAFEWORK PROCEDURES

6.3.1 General
Safework procedures shall be developed by the owner and incorporated into the operation
of the conveyors or conveyor systems.
6.3.2 Access or work in a danger zone
Access to, or work in, a danger zone shall not be permitted while the conveyor is running.
Where any access or work, except in accordance with Clause 6.3.3, is to be undertaken in a
danger zone, the procedures shall include energy isolation of the conveyor by operation of
the main isolation device (see Clause 2.7.3). All other sources of energy associated with the
conveyor and which may create a hazard shall also be isolated in an appropriate manner.
6.3.3 Work using remote isolating device

When using a remote isolating device (see Clause 2.7.4) to isolate the conveyor, before any
work is undertaken in a danger zone a specific risk assessment shall be carried out to
establish whether this isolation method is appropriate for the work to be undertaken and
safe work procedures shall be established.
The risk assessment undertaken for this purpose shall have due regard to the limits of the
work to be undertaken, consequence, hazard exposure time and the potential for failure of
the isolation or pre-start warning systems.
Where work using a remote isolating device is undertaken on a conveyor, a sign clearly
stating the work that can be undertaken and a warning that the device is not to be used for
other purposes, shall be placed in a conspicuous position affixed to the device.
6.3.4 Isolation systems
The system of isolation adopted should incorporate a tagging system, a locking system or
permit system and in any case shall also include a method for ensuring that isolation is
effectively established.
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6.3.5 Installation, commissioning and dismantling procedures

These procedures shall cover all work to be undertaken by trained and competent personnel
involved with the installation, commissioning and dismantling of conveyors and shall
include
(a)
site establishment including induction and training;
(b)
materials handling;
(c)
work methods;
(d)
minimum acceptance standards;
(e)
emergency plans;
(f)
documentation; and
(g)
modifications or repairs.
6.3.6 Operating procedures

These procedures shall cover all work to be undertaken by trained competent operators and
shall include
(a)
pre-checks;
(b)
hazard control;
(c)
isolation;
(d)
loading and unloading;
(e)
emergency;
(f)
shutdown; and
(g)
normal start/stop.
6.3.7 Maintenance procedures
These procedures shall cover all work to be undertaken by trained competent maintenance
personnel and shall include operating aspects contained in Clause 6.3.5 and the following:
(a)
Isolation requirements for the type of maintenance being undertaken.
(b)
Access incorporating the removal and replacement of guards.
(c)
Competent replacement and repair.
(d)
Use of materials.
(e)
Use of tools and test equipment.
(f)
Housekeeping.
(g)
Inspection and periodic adjustments.
(h)
Breakdown activities.
(i)
Recording and documenting activities.
6.3.8 Maintenance management

A maintenance management program shall be incorporated into the operation of conveyors
or conveyor systems to ensure satisfactory operation while in service.
The program shall include but is not limited to the following:
(a)
Pre-operational servicing including lubrication requirements.
(b)
Periodic and or condition based servicing.
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(c)
Periodic inspections.
(d)
Testing and inspection of safety equipment.
(e)
Records, including but not limited to reporting overloads and damage.
(f)
Compliance auditing.
AS 17552000
6.4 TRAINING
Competency based training shall be provided for installers, commissioners, dismantlers,
operators and maintenance personnel and other persons exposed to a hazard from a
conveyor. Such training shall be relevant to the procedures associated with installation,
commissioning, dismantling, operating and maintenance of the conveyor or conveyor
system.
This training shall include but is not limited to the following:
Safework practices including isolation procedures.
(b)
Emergency procedures.
(c)
Correct operation of the conveyor.
(d)
Hazard identification, reporting, control and management.
(e)
Reasons for protective devices including guards.
(f)
Selection and care of personal protective equipment.
(g)
Need for good housekeeping.
(h)
Statutory requirements.
(i)
Electrical and mechanical safety.
(j)
Document management and control.
(a)
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APPENDIX A
GLOSSARY OF CONVEYOR TERMS

(Normative)
NOTE: The terms and definitions applicable to conveyors and conveying systems set out in this
Appendix are accompanied by typical configurations for the purpose of clarity. However, this
does not exclude other arrangements that achieve the same effect.
A1 ANTI-RUNBACK DEVICES
A1.1 Anti-runback device for belt conveyors
Consists of a full complement of shaped steel sprags or wedges, located in the annular
space between concentric inner and outer races. Power is transmitted from one race to the
other by the wedging action of the sprags between them. Rotation of one race in the
driving direction causes the sprags to tilt, thus transmitting the torque in full from one
race to the other. Conversely, rotation of the race in the other direction frees the sprags and
permits overrunning between the races (see Figure A1).
FIGURE A1 ANTI-RUNBACK DEVICE
A1.2 Anti-runback device for overhead chain conveyor
A mechanical device to prevent reversal of a loaded conveyor under action of gravity when
forward travel is interrupted (see Figure A2).
FIGURE A2 UPHILL SAFETY STOP

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A1.3 Anti-runaway device for overhead chain conveyor

A mechanical safety device to lock or catch the conveyor and prevent running away in the
direction of travel in the case of failure (see Figure A3).
FIGURE A3 DOWNHILL RUNAWAY STOP
A2 APRON CONVEYORS
A2.1 Apron conveyor
A conveyor composed of interlocking or overlapping, flat or shaped plates, carried on

chains and running on tracks (see Figure A4).
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FIGURE A4 APRON CONVEYOR
A2.2 Apron conveyor with pans
An apron conveyor in which the sides and ends of the plates are turned upwards to form
open pans (see Figure A5).
FIGURE A5 APRON CONVEYOR WITH PANS
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A3 BELT CONVEYORS
A3.1 Belt conveyor
A conveyor using a moving belt for the conveying medium. The belt is usually driven by a
drum at one end, passing over a free-running drum at the other end. The upper portion of
the belt may be supported by free-running idlers or suitable flat surfaces. This type of
conveyor can be arranged for horizontal or inclined travel, the angle of slope depending on
the character of the goods conveyed and the type of belt surface (see Figure A6).
FIGURE A6 BELT CONVEYOR
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A3.2 Fixed belt conveyor

A stationary mechanical item of plant designed for the conveying of materials and fitted
with an endless belt of fabric, rubber, plastics, leather, or metal (see Figure A7).
FIGURE A7 FIXED BELT CONVEYOR
A3.3 Mobile belt conveyor
A mobile conveyor with either adjustable or non-adjustable heights on wheels which is not
self-propelled but carries continuous handling equipment (see Figure A8).
FIGURE A8 MOBILE BELT CONVEYOR

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AS 17552000
A3.4 Portable belt conveyor

A portable conveyor with adjustable heights on stands, carrying continuous handling
equipment (see Figure A9).
FIGURE A9 PORTABLE BELT CONVEYOR
A3.5 Belt conveyor, thrower or spreader

A short high-speed belt conveyor, capable of throwing loose bulk material into otherwise
inaccessible areas (see Figure A10).
FIGURE A10 THROWER OR SPREADER
A3.6 Closed belt conveyor

A conveyor composed of a moving belt capable of being formed into a closed tubular shape.
While in motion the belt opens to receive the load, closes to convey it, and opens to
discharge it (see Figure A11).
FIGURE A11 CLOSED BELT CONVEYOR

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A3.7 Telescopic belt conveyor

A continuous belt consisting of a series of pulleys which permit extension or retraction of
the conveyor length (see Figure A12).
FIGURE A12 TELESCOPIC BELT CONVEYOR
A3.8 Chain or wire rope belt conveyor
A conveyor composed of a belt secured to transverse supports carried by moving wire ropes
or chains. The chains or wire ropes transmit the driving force, the belt forming the loadcarrying medium (see Figure A13).
FIGURE A13 BELT CONVEYOR SUPPORTED AND MOVED

BY WIRE ROPES OR CHAINS
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A3.9 STEEL BAND CONVEYOR

A belt conveyor in which the carrying medium is a thin flexible steel band
(see Figure A14).
FIGURE A14 STEEL BAND CONVEYOR
A3.10 WALLED BELT CONVEYOR
A conveyor consisting of a moving belt having a flat carrying face extended to form side
walls of limited height (see Figure A15).
FIGURE A15 WALLED BELT CONVEYOR
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A4 BARREL OR DRUM CONVEYOR

A conveyor with arms fixed to the chains which may be set at a moderate angle to the
vertical. Loading can occur at any intermediate floor but unloading can only occur as the
arms pass over the top of the chain sprockets and discharge the load (see Figure A16).
FIGURE A16 BARREL OR DRUM CONVEYOR
A5 BUCKET CONVEYORS
A5.1 Bucket elevator
A conveyor for loose bulk materials with buckets as the carrying medium attached to a belt
or chains as the driving medium (see Figure A17).
FIGURE A17 BUCKET ELEVATOR

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A5.2 Gravity bucket conveyor

A conveyor consisting of freely swinging buckets carried between parallel endless chains,
the buckets being tipped to discharge contents. The centre of gravity of the bucket is below
the centre-line of the chain pivot and thus the chain may follow any path from horizontal to
vertical with the buckets continuing to hang vertically. Feeding of the buckets may be either
by gravity or by means of a suitable rotary feeder (see Figure A18).
FIGURE A18 GRAVITY BUCKET CONVEYOR
A5.3 Pivoted bucket conveyor

A conveyor using pivoted buckets attached between two endless chains. The buckets remain
in a carrying position until tipped or inverted to discharge (see Figure A19).
FIGURE A19 PIVOTED BUCKET CONVEYOR
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A5.4 Vertical internal discharge chain and bucket conveyor

A totally enclosed continuous bucket conveyor with the bucket carried between two chains
and having inner openings. The material is fed in at the foot of the conveyor and discharge
occurs when the buckets are inverted while passing over the head sprockets, the material
being delivered by means of a chute passing through a conveyor casing (see Figure A20).
FIGURE A20 INTERNAL DISCHARGE CHAIN AND BUCKET CONVEYOR
A6 CHAIN CONVEYORS
A6.1 Chain conveyor
A conveyor for unit loads, with an endless driving medium, e.g. chain or cable, and a series
of trolleys supported by an overhead track.
A6.2 Chain conveyor with driving dogs
A chain conveyor with pusher dogs driving load-carrying trucks on a separate track or floor
(see Figure A21).
FIGURE A21 CHAIN CONVEYOR
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A6.3 Drag chain conveyor

A conveyor having one or more endless chains which drag bulk materials in a trough
(see Figure A22).
FIGURE A22 DRAG CHAIN CONVEYOR
A6.4 Overhead chain conveyor (open track type)

A conveyor which uses a biplanar chain suspended by wheeled trolleys which run on an
overhead track (see Figure A23).
FIGURE A23 OVERHEAD OPEN TRACK CHAIN CONVEYOR
A6.5 Overhead chain conveyor (enclosed track)

A chain conveyor which uses a biplanar articulated chain which serves to transmit driving
tension and carries the weight of the load. It has rollers disposed in the vertical and
horizontal planes running in an enclosed track (see Figure A24).
FIGURE A24 OVERHEAD ENCLOSED TRACK CHAIN CONVEYOR

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A6.6 Single chain or crate conveyor

A conveyor with a centrally located chain as the driving medium (see Figure A25).
FIGURE A25 SINGLE CHAIN OR CRATE CONVEYOR
A6.7 Swing chain conveyor, fork tray type
A conveyor consisting of freely swinging finger type trays carried between parallel endless
chains which swing at the change of direction to pick up on the feed side and discharge the
feed on the downward side. The drive is generally at the head of the conveyor, the chains
passing over sprockets of considerable diameter. Loading or unloading can be made
automatic and can occur at any intermediate floor level (see Figure A26).
FIGURE A26 FORK TRAY SWING CHAIN CONVEYOR
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A6.8 Swing tray conveyor, solid tray type

A vertical conveyor having one or more endless chains with suitable pendant trays, or
carriers which receive and deliver packages or objects at one or more elevations
(see Figure A27).
FIGURE A27 SOLID TRAY SWING CHAIN CONVEYOR
A6.9 Roller flight conveyor (accumulating)
A conveyor having double strands of chain connected by spindles supporting freely rotating
load-carrying rollers (see Figure A28).
FIGURE A28 ACCUMULATING ROLLER FLIGHT CONVEYOR
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A6.10 Vertical chain conveyor, opposed shelf type

Two or more elevating conveying units opposed to each other. Each unit consists of one or
more endless chains whose adjacent facing runs operate in parallel paths so that pairs of
opposing shelves or brackets are synchronized to receive packages or trays and deliver them
at any number of elevations. (The auto-unload type is illustrated in Figure A29.)
FIGURE A29 OPPOSED SHELF VERTICAL CHAIN CONVEYOR
A6.11 Flight conveyor (push-type)

A conveyor comprising one or more endless chains or links to which flights are attached
(see Figure A30).
FIGURE A30 PUSH TYPE FLIGHT CONVEYOR

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A6.12 Pallet type conveyor

A conveyor assembled from a series of flat or shaped wheelless carriers propelled by and
attached to one or more endless chains or other linkage (see Figure A31).
FIGURE A31 PALLET CONVEYOR
A7 CROSS-BAR CONVEYOR
A conveyor consisting of two strands of chain connected together by fixed bars from which
unit loads are suspended (see Figure A32).
FIGURE A32 CROSS BAR CONVEYOR
A8 DISC OR BUTTON CONVEYOR

A conveyor composed of a wire rope or chains carrying discs or buttons and operating in a
V-shaped trough (see Figure A33).
FIGURE A33 DISC OR BUTTON CONVEYOR
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A9 FLIGHT CONVEYOR (RECIPROCATING)

A conveyor consisting
(see Figure A34).
of
reciprocating
beam
with
attached
hinged
flights
FIGURE A34 RECIPROCATING FLIGHT CONVEYOR
A10 POCKET CONVEYOR

A conveyor consisting of a series of pockets made of flexible materials and festooned
between cross-rods carried by two endless chains or other linkage (see Figure A35).
FIGURE A35 POCKET CONVEYOR
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A11 TRUCK-TOWING CONVEYORS

A11.1 Floor truck-towing conveyor
A moving endless chain or wire rope carried in a trench and mounted above or below floor
level, to which load carrying tow trucks are attached by means of a retractable pin
(see Figure A36).
FIGURE A36 FLOOR TRUCK-TOWING CONVEYOR
A11.2 Single strand floor-mounted truck conveyor
A conveyor for unit loads with a single strand chain or wire rope under or above floor level
as the driving medium (see Figure A37).
FIGURE A37 SINGLE STRAND FLOOR-MOUNTED TRUCK CONVEYOR
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A12 MAGNETIC CONVEYOR

A conveyor having a flexible rubber or canvas belt moving adjacent to a static magnetic
field which imparts a retaining influence or pull to any magnetizable article and so allows
the belt to move the article through vertical and horizontal planes (see Figure A38).
FIGURE A38 MAGNETIC CONVEYOR
A13 OSCILLATING CONVEYOR

A conveyor similar to a vibrating conveyor but of the slow-speed type, using an eccentric
crankshaft to move the trough or tube (see Figure A39).
FIGURE A39 OSCILLATING CONVEYOR
A14 PLATE CONVEYOR

A continuous conveyor for loose bulk materials or unit loads (see Figure A40).
FIGURE A40 PLATE CONVEYOR
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AS 17552000
A15 POWERED ROLLER CONVEYOR

A series of rollers over which packages or objects are moved by the application of suitable
power means to all or a part of the rollers (see Figure A41).
FIGURE A41 POWERED ROLLER CONVEYOR
A16 RECIPROCATING BEAM CONVEYOR
A conveyor assembled with one or more reciprocating beams with tilting dogs or pushers
(see Figure A42).
FIGURE A42 RECIPROCATING BEAM CONVEYOR
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A17 SCREW CONVEYORS (See Figure A43)

A17.1 Screw conveyor
A conveyor for loose bulk materials with a trough or tube as the carrying medium, the
material being transported by the action of a rotating helix or broken screw (paddle type).
A17.2 Screw tube conveyor
A screw conveyor for transporting bulk materials by means of a close-bladed screw.
FIGURE A43 SCREW CONVEYOR
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AS 17552000
A17.3 Vertical screw tube conveyor

A screw conveyor for transporting bulk materials vertically (see Figure A44).
FIGURE A44 VERTICAL SCREW TUBE CONVEYOR
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AS 17552000
72
A17.4 Screw conveyor, trough type

A revolving pipe or shaft on which is mounted helically shaped flighting which serves to
convey bulk materials along the trough or a defined path (see Figure A45).
FIGURE A45 TROUGH TYPE SCREW CONVEYOR
A17.5 Screw conveyor, paddle type

A screw conveyor which is similar to the full-bladed type, but the conveying elements are
in the form of separate paddles of various shapes attached to the central shaft in a helical
pattern, allowing mixing of the material during conveying (see Figure A46).
FIGURE A46 PADDLE TYPE SCREW CONVEYOR
A17.6 Screw conveyor, ribbon type
A screw conveyor which is similar to the full-bladed type except that the helix is in the
form of a ribbon attached to the central shaft by palm-bolts (see Figure A47).
FIGURE A47 RIBBON TYPE SCREW CONVEYOR
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AS 17552000
A18 SHUTTLE CONVEYOR

Any conveyor such as a belt, chain, pan, apron, screw and the like in a self-contained
structure movable in a defined path parallel to the flow of the material (see Figure A48).
FIGURE A48 SHUTTLE CONVEYOR
A19 SLAT CONVEYORS

A19.1 Slat conveyor
One or more endless chains to which non-overlapping, non-interlocking spaced slats are
attached to form a moving support for the packages or objects being conveyed
(see Figure A49).
FIGURE A49 SLAT CONVEYOR
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A19.2 Slat conveyor with pushers

A slat conveyor for loose bulk materials or unit loads with slats and pushers as the carrying
medium and with chains as the driving medium (see Figure A50).
FIGURE A50 SLAT CONVEYOR WITH PUSHERS
A19.3 Slat band conveyor
A light duty flat top conveyor in which small hinged plates serve as both the chain and the
work carrying plates. This conveyor provides a flat, smooth and level surface commonly
used to transport cans and bottles (see Figure A51).
FIGURE A51 SLAT BAND CONVEYOR
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AS 17552000
A20 TWIN FLAT TOP CONVEYOR

A conveyor which utilizes two heavy duty flat top lines commonly set flush in the floor and
driven by a single head shaft to transport large, heavy, or wide objects such as a complete
motor vehicle, rolls of paper or sheet steel (see Figure A52).
FIGURE A52 TWIN FLAT TOP CONVEYOR
A21 HINGED SECTION

A hinged section, inserted in a roller conveyor, and counterbalanced to facilitate the upward
tilting of the section to produce a clear way through the conveyor track (see Figure A53).
FIGURE A53 HINGED SECTION
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A22 TRIPPER
A moveable part of a conveyor, typically mounted on wheels, used for discharging material
at selected locations along its length (see Figure A54).
FIGURE A54 TRIPPER
A23 TROLLEY CONVEYOR
A conveyor consisting of a series of trolleys supported from or within an overhead track

connected by an endless chain, cable, or other linkage with loads suspended from the
trolleys (see Figure A55).
FIGURE A55 TROLLEY CONVEYOR
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AS 17552000
A24 VIBRATING CONVEYOR

A trough or tube flexibly supported and vibrated to convey bulk material or objects
(see Figure A56).
FIGURE A56 VIBRATING CONVEYOR
A25 WIRE MESH BELT CONVEYOR

A conveyor in which the carrying medium is of mesh construction, either flat or troughed,
while the conveyor itself may be straight or curved (see Figure A57).
FIGURE A57 WIRE MESH BELT CONVEYOR
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AS 17552000
78
APPENDIX B
REFERENCED DOCUMENTS
(Normative)
The following documents are referred to in this Standard:
AS
1121
Guards for agricultural tractor PTO drives
1318
Use of colour for the marking of physical hazards and the identification of
certain equipment in industry (known as the SAA Industrial Safety Colour
Code)
1319
Safety signs for the occupational environment
1332
Conveyor beltingTextile reinforced
1333
Conveyor belting of elastomeric and steel cord construction
1334
1334.9
Methods of testing conveyor and elevator belting

Part 9: Determination of electrical resistance of conveyor belting
1657
Fixed platforms, walkways, stairways and laddersDesign, construction and

installation
1680
1680.2.1
Interior lighting
Part 2.1: Circulation spaces and other general areas
2380
Electrical equipment
techniques (all Parts)
2430
Classification of hazardous areas (all Parts)
2759
Steel wire ropeApplication guide
2865
Safe working in a confined space
3569
Steel wire ropes
3997
3997.2
Fluid powerFire resistant hydraulic fluids

Part 2: Guidance on the selection, use and storage
4024
4024.1
Safeguarding of machinery
Part 1: General principles
AS/NZS
1020
The control of undesirable static electricity
2381
for
explosive
atmospheresExplosion-protection
2381.1
Electrical equipment for explosive atmospheresSelection, installation and

maintenance
Part 1: General requirements
3000
Electrical installations (known as the Australian/New Zealand Wiring Rules)
3931
Risk analysis of technological systemsApplication guide
4360
Risk management
ISO
7745
Hydraulic fluid powerFire resistant (FR) fluidsGuidelines for use
Worksafe
Australia
NOHSC:1001
(1990)
Standards Australia
National Standard for Manual Handling
79
AS 17552000
APPENDIX C
ERGONOMIC DATA
(Normative)
C1 GENERAL
The data below are for users who need to design and build guards that prevent persons from
encroaching into a danger zone associated with a machine.
They are taken from AS 4024.11996, and the most recently published version of that
Standard should be used, except for the specific variations detailed in Figure C4 herein.
Users should carefully consider whether the data are appropriate for use with the specific
workforce which may be taller, shorter or thinner than the population from which the data
were taken.
Where doubt exists, measurements of the workforce may be taken and careful trials made to
ensure that the danger points are beyond reach. Where such trials are made, the machinery
shall be in a safe condition during the trials.
C2 REACHING UP
With the body upright and standing at full height, the minimum safety distance when
reaching upward is 2500 mm (see Figure C1).
FIGURE C1 SAFETY DISTANCE FOR REACHING UP
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C3 UPPER LIMB REACH DISTANCE WITH FIXED FENCES

C3.1 General
Selection of the appropriate safety distance for reaching over a fixed fence shall depend on
a risk assessment. The assessment shall be based on the probability of occurrence of injury
and the likely severity of that injury.
C3.2 Reaching down and over
When reaching down over an edge, e.g. on machine frames or barriers, the safety distance is
found from Figure C2.
NOTE: Attention is drawn to the increased danger of overbalancing when reaching over a 1 m
high barrier.
C3.3 Reaching under
Where clearance is provided under a guard for cleaning spillages, swarf and similar, the
clearance should not exceed 200 mm. (See also Figure C3.)
Standards Australia
AS 17552000
81
Height of
danger zone
( h)
Horizontal distance to danger zone ( s)

Height of protective structure ( u)*
1 000
1 200
1 400
1 600
1 800
2 000
2 200
2 400
2 500
2 500
2 400
100
100
100
100
100
100
100
100
2 200
600
600
500
500
400
350
250
2 000
1 100
900
700
600
500
350
1 800
1 100
1 000
900
900
600
1 600
1 300
1 000
900
900
500
1 400
1 300
1 000
900
800
100
1 200
1 400
1 000
900
500
1 000
1 400
1 000
900
300
800
1 300
900
600
600
1 200
500
400
1 200
300
200
1 100
200
1 100
200
* Protective structures less than 1000 mm height are not included because they do not sufficiently
restrict movement of the body.
Protective structures having a height of 1600 mm and less should only be used where a risk
assessment indicates low probability and low severity of injury.
NOTES:
1
There should be no interpolation of the values in the Table.
Barriers are not foolproof and they cannot prevent access to persons intent on gaining access. Therefore, as a
person's intent on reaching a dangerous part increases, e.g. by climbing on chairs, ladders or the barrier
itself, the protection provided by a barrier decreases.
FIGURE C2 GUARD DISTANCES
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C4 REACHING AROUND WITH UPPER LIMBS

When reaching around edges in any position, the safety distance of freely articulating upper
limbs is given in Figure C3.
The radius of the movement about a fixed edge is determined by the reach of given body
parts. The safety distances assigned should be respected as a minimum if the body part
concerned is not to be allowed to reach a danger point.
Of special importance is the danger area which can be reached when these body parts are
introduced through slots.
When applying safety distances, it is to be assumed that the basic joint component of the
relevant body part is in fixed contact with the edge. The safety distances apply only if it is
ensured that further advance or penetration of the body part towards the danger point is
excluded.
Limitation of movement
Safety
distance (sr)
Limitation of movement only at

shoulder and -armpit
850
Arm supported up to elbow
550
Arm supported up to wrist
230
Arm and hand supported up to

knuckle joint
130
Illustration
* Either the diameter of a round opening, the side of a square opening or the width of a slot
opening.
FIGURE C3 SAFETY DISTANCES FOR REACH ROUND
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C5 REACHING IN AND THROUGH REGULAR OPENINGS WITH UPPER LIMBS

Safety distances are as given in Figure C4. The dimension of openings (e) correspond to the
side of a square opening, the diameter of a round opening or the narrowest dimension of an
elongated opening or slot.
Should any opening allow access past the shoulder, safety distances shall be selected using
Figure C2.
Part of body
Fingertip
Finger up to
knuckle joint or
hand
Arm up to
junction with
shoulder
Illustration
Safety distance ( sr )
Opening
Slot
Square
Round
e4
4<e6
10
6<e8
20
15
8 < e 10
80
25
20
10 < e 12
100
80
80
12 < e 20
120
120
120
20 < e 30
850
120
120
30 < e 40
850
200
120
850
850
850
30 < e 50*
40 < e 120
50 < e 120*
* For mining operations
FIGURE C4 REACHING IN AND THROUGH REGULAR OPENINGS
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C6 OPENINGS OF IRREGULAR SHAPE

To choose a safety distance for upper limbs entering an opening of irregular shape, the
following procedure shall be followed:
(a)
(b)
Determine
(i)
the diameter of the smallest round opening;
(ii)
the side of the smallest square opening; and
(iii)
the width of the narrowest slot opening into which the irregular opening can be
inserted (see Figure C5).
Select the corresponding safety distances from Figure C4.

NOTE: The shortest safety distance of the values selected may be used.
C7 LOWER LIMB REACH DISTANCE

C7.1 General
The data given in Figure C6 may be used where the risk assessment shows that there is a
risk only to the lower limbs. Where there is a risk to both upper and lower limbs, then the
longest safety distance appropriate to the aperture size and given in Figure C4 or Figure C6
shall be used.
C7.2 Reaching in and through regular openings
The dimension of openings (e), corresponds to the side of a square opening, the diameter of
a round opening or the narrowest dimension of an elongated opening or slot.
FIGURE C5 IRREGULAR-SHAPED OPENING
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Part of lower
Illustration
Opening
Safety distance (sr)
limb
Slot
Square or round
e5
5 < e 15
10
15 < e 35
80*
25
35 < e 60
180
80
60 < e 80
650
180
Leg up to knee
80 < e 95
1 100
650
Leg up to crotch
95 < e 180
1 100
1 100*
180 < e 240
not
admissible
1 100
Toe tip
Toe
Foot
* If the length of the slot opening is 75 mm the distance can be reduced to 50 mm.
The value corresponds to leg up to knee.
The value corresponds to leg up to crotch.
FIGURE C6 REACHING IN AND THROUGH REGULAR OPENINGS

WITH THE LOWER LIMBS
C8 MINIMUM GAPS TO PREVENT CRUSHING
A crushing hazard will be generated if either two movable parts are moving towards one
another, or one movable part is moving towards a fixed part.
The minimum gap dimensions to minimize the risk from a crushing hazard are given in
Figure C7. Care must be taken to assess the risk of a person entering the crush zone in a
different body orientation to those given. Where such a risk is considered to be
unacceptable, additional measures will be required to minimize the risk, e.g. the use of
fixed barriers to prevent access.
In addition, consideration should be given to the increase in hand or body part dimensions
as a result of holding tools or workpieces, or from the use of personal protective equipment
such as gloves or helmets.
C9 MANUAL HANDLING
Specific guidance on manual handling is beyond the scope of this Standard. However
attention is drawn to NOHSC:1001 (1990).
Standards Australia
AS 17552000
Part of
body
86
Minimum
gap (e)
Illustration
Part of
body
Minimum
gap (e)
Body
500
Toes
50
Head
(least
favourable
position)
300
Arm
120
Leg
180
Hand
100
Illustration
Wrist
Fist
Foot
120
Finger
25
FIGURE C7 MINIMUM GAPS TO PREVENT CRUSHING
Standards Australia
Standards Australia
Standards Australia is an independent company, limited by guarantee, which prepares and publishes
most of the voluntary technical and commercial standards used in Australia. These standards are
developed through an open process of consultation and consensus, in which all interested parties are
invited to participate. Through a Memorandum of Understanding with the Commonwealth government,
Standards Australia is recognized as Australias peak national standards body.
Australian Standards
Australian Standards are prepared by committees of experts from industry, governments, consumers
and other relevant sectors. The requirements or recommendations contained in published Standards are
a consensus of the views of representative interests and also take account of comments received from
other sources. They reflect the latest scientific and industry experience. Australian Standards are kept
under continuous review after publication and are updated regularly to take account of changing
technology.
International Involvement
Standards Australia is responsible for ensuring that the Australian viewpoint is considered in the
formulation of international Standards and that the latest international experience is incorporated in
national Standards. This role is vital in assisting local industry to compete in international markets.
Standards Australia represents Australia at both ISO (The International Organization
for Standardization) and the International Electrotechnical Commission (IEC).
Electronic Standards
All Australian Standards are available in electronic editions, either downloaded individually from our Web
site, or via on-line and CD ROM subscription services. For more information phone 1300 65 46 46 or
visit us at
GPO Box 5420 Sydney NSW 2001

Administration Phone (02) 8206 6000 Fax (02) 8206 6001 Email mail@standards.com.au
Customer Service Phone 1300 65 46 46 Fax 1300 65 49 49 Email sales@standards.com.au
Internet www.standards.com.au
ISBN 0 7337 3588 6
Printed in Australia
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AS 17552000

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

This Australian Standard was prepared by Committee EL/23, Electrical Equipment

The following interests are represented on Committee EL/23:

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

WorkCover New South Wales

Keeping Standards up-to-date

This Standard was issued in draft form for comment as DR 97349.

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

adding a Section dealing with requirements for specific applications, notably

adding, as an appendix, ergonomic data.

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

SECTION 3 REQUIREMENTS FOR GUARDING

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specific types such as belt conveyors and mobile or transportable conveyors.

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

The requirements of this Standard are intended to be used by designers, manufacturers,

1.4 SECTION REQUIREMENTS

an endless belt, rope or chain or other similar means;

a vibrating or walking beam; or

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

1.6.5 Danger zone

1.6.9 Fixed guarding

1.6.13 Mobile conveyor

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Accessed by DOWNER EDI LIMITED on 12 Jul 2006

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

2.2.3.2 Anti-runaway device

2.2.3.3 Prevention of hazardous movement

2.2.6 Hinged section

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

Means should be provided at the discharge point of a conveyor to minimize carry

Dust cover hoods.

Dust collections systems.

Horizontal areas on which dust can accumulate should be minimized.

2.3 ACCESS TO CONVEYORS

2.3.3 Working clearance

2.7 CONVEYOR CONTROL AND ISOLATION FACILITIES

FIGURE 2.1 PHASES IN THE DESIGN PROCESS

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

2.7.3 Main isolating device

direct isolation of the energy source, or

indirect isolation of the energy source via a control system.

A prestart warning in accordance with Clause 2.7.5 shall be provided.

2.7.5 Prestart warning systems

A non-reprogrammable interposing device (e.g. relays, including electronic relays).

A programmable interposing device for other than emergency stop controls.

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2.7.7 Emergency stop controls

At positions adjacent to the conveyor at which the conveyor can be started.

At every permanent working station.

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

2.7.9 Pull wire requirements

Where electrical continuity is monitored in the pull wire

the slackening requirement of Item (a) need not apply; and

readily accessible from all areas of access to the conveyor;

at least 900 mm above the access floor;

generally not more than 1500 mm above the access floor;

where it is possible for a person to be inadvertently on a moving conveyor, an

See Figure 2.3 for the preferred location of pull wires.

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

Accessed by DOWNER EDI LIMITED on 12 Jul 2006

FIGURE 2.2 EMERGENCY STOP PULL WIREOPERATING DIRECTION