MAN/General/TBT-MAN-020

Conveyor Systems for Materials

Manual Handling › General › Conveyor Systems for Materials

Presenter		Project
Location		Date

Conveyor systems transport bulk materials such as aggregate, concrete, and spoil across construction sites.
Nip points between the belt and rollers are the primary cause of serious injuries including amputations.
All conveyor systems must have emergency stop pull cords running the full length of the belt.
Guards must be in place over drive drums, tail drums, return rollers, and all accessible nip points.
The Provision and Use of Work Equipment Regulations 1998 (PUWER) require guarding and maintenance of all conveyors.
Material spillage from conveyors creates slip and trip hazards and can bury workers beneath the discharge point.
Conveyor belt tracking must be maintained to prevent material falling from the edges and damaging components.
Lockout and isolation of the drive motor is mandatory before any maintenance, cleaning, or adjustment work.
Conveyors operating at height require fall protection for workers accessing walkways, platforms, and transfer points.
Dust generation from dry materials on conveyors requires suppression or extraction at loading and transfer points.

Prevent amputation	Unguarded nip points between belts and rollers catch clothing and limbs, causing devastating crush and amputation injuries.
PUWER compliance	PUWER 1998 requires all dangerous parts of conveyors to be guarded and emergency stops to be accessible.
Burial risk	Material accumulation beneath conveyors and at discharge points can collapse and bury workers standing below.

Don't

Check all guards are in place over drums, rollers, and nip points before starting the conveyor
Test the emergency stop pull cord operates correctly before each shift of conveyor operation
Isolate and lock out the drive motor before any maintenance, cleaning, or belt adjustment
Maintain clear walkways along conveyor routes and under transfer and discharge points
Wear hearing protection near conveyors where noise levels exceed 85 dB(A) during operation
Suppress dust at loading and transfer points using water sprays or extraction systems
Keep the area beneath conveyors clear of accumulated material to prevent burial hazards
Use fall protection when accessing elevated conveyor walkways and platform areas
Report any belt tracking problems, spillage, or unusual noises to the supervisor immediately
Ensure only trained and authorised persons operate or maintain conveyor systems on site

DON'T reach into nip points between the belt and rollers while the conveyor is running
DON'T remove or bypass guards on drums, rollers, or drive mechanisms for any reason
DON'T carry out maintenance or cleaning without locking out and isolating the drive motor
DON'T stand beneath conveyor discharge points where material could fall and bury you
DON'T attempt to clear blockages while the conveyor belt is still running
DON'T wear loose clothing, jewellery, or dangling lanyards near moving conveyor components
DON'T walk across conveyor belts — use the designated crossing points or walkways provided
DON'T disable or tie off the emergency stop pull cord system along the conveyor length
DON'T allow material to accumulate under conveyors to the point where it contacts the belt
DON'T allow untrained persons to start, stop, or adjust conveyor operating settings

See also: LOTO Awareness | Plant and Pedestrian Segregation

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