Crusher Safety

Crushers  First step in converting shot rock into usable products  Taking large rocks & reducing them to small pieces  Primary  Secondary  First step in converting shot rock into usable products  Taking large rocks & reducing them to small pieces  Primary  Secondary

Primary crushers reduces rock to manageable size

Secondary crushers reduce rock into smaller sized product

Secondary Crushers  Crushing done in two or three steps  primary crusher followed by secondary crusher & tertiary crushing  Crushing done in two or three steps  primary crusher followed by secondary crusher & tertiary crushing

Raw material brought to primary by haul trucks

Crushers Types  Jaw  Impact  Roll  Gyratory  Jaw  Impact  Roll  Gyratory

Dust Hazards  Crusher operators exposed to high levels of dust  Long-term exposure can lead to silicosis  Crusher operators exposed to high levels of dust  Long-term exposure can lead to silicosis

Dust Control  Booths separate workers from dust  Water to suppress dust  Local ventilation – captures & carries dust away from workers  Booths separate workers from dust  Water to suppress dust  Local ventilation – captures & carries dust away from workers

Flying Material  Can spray pieces of rock in all directions  Crushers have heavy metal casings around them to help keep material from being thrown  Can spray pieces of rock in all directions  Crushers have heavy metal casings around them to help keep material from being thrown

Surge Bins  Material that falls, slides or rolls from surge bins is dangerous  Most crushers automated, but workers needed to clear clogs, check operations & maintain machinery  Material that falls, slides or rolls from surge bins is dangerous  Most crushers automated, but workers needed to clear clogs, check operations & maintain machinery

Slips & Falls  Slips & falls common crusher injuries  Spillage can cause falls  Cluttered walkways  Slips & falls common crusher injuries  Spillage can cause falls  Cluttered walkways

Operating Safety  Crushers move rapidly and powerfully  Not tampered with while operating  Strains, sprains, crushed limbs or fatal injuries result from people maintaining running machines  Crushers move rapidly and powerfully  Not tampered with while operating  Strains, sprains, crushed limbs or fatal injuries result from people maintaining running machines

Noise  Noise levels reduced by:  Operator booths  Ear plugs or ear muffs  Noise levels reduced by:  Operator booths  Ear plugs or ear muffs

Supply  Crushers require constant supply  Conveyers & haul equipment increase risk  Crushers require constant supply  Conveyers & haul equipment increase risk

Safe Job Procedures

PPE  Hardhat  Safety Boots  Safety Glasses  Gloves  Hardhat  Safety Boots  Safety Glasses  Gloves  Hearing Protection  Respirator  Fall protection

Start-Up Inspection  Hazard: –Slips –Trips –Falls  Hazard: –Slips –Trips –Falls

Start-Up Inspection  Safe procedure: –Housekeeping –Walkways clear –Clean up spills  Safe procedure: –Housekeeping –Walkways clear –Clean up spills

Check Crusher  Hazard: –Grease & oil leakage  Hazard: –Grease & oil leakage

Check Crusher  Safe procedure: –Inspect for loose bolts & nuts –Cracks in housing or supports  Safe procedure: –Inspect for loose bolts & nuts –Cracks in housing or supports

Start Crusher & Feed  Hazard: –Person caught in equipment –Belt breaking  Hazard: –Person caught in equipment –Belt breaking

Start Crusher & Feed  Safe procedure: –Personnel clear –Check belts to ensure in good condition  Safe procedure: –Personnel clear –Check belts to ensure in good condition

Watch Trucks Dump  Hazard: –Material flying & hitting personnel –Live explosives  Hazard: –Material flying & hitting personnel –Live explosives

Watch Trucks Dump  Safe procedure: –Area clear of personnel –If dynamite or cap observed in rock, do not try to remove it –Shut off crusher & feeder - call supervisor  Safe procedure: –Area clear of personnel –If dynamite or cap observed in rock, do not try to remove it –Shut off crusher & feeder - call supervisor

Free Large Rocks  Hazard: –Equipment starting –Falling rock –Fall into crusher –Pry bar slipping –Eye injuries –Sledge hammer glancing  Hazard: –Equipment starting –Falling rock –Fall into crusher –Pry bar slipping –Eye injuries –Sledge hammer glancing

Free Large Rocks  Safe procedure: –Lockout & tagout –Barricade truck dump –Use harness & line –Wear eye protection –Use short handled hammer in close places  Safe procedure: –Lockout & tagout –Barricade truck dump –Use harness & line –Wear eye protection –Use short handled hammer in close places

Signal For Start-Up  Hazard: –Excess material –Crush or injure personnel due to excess material  Hazard: –Excess material –Crush or injure personnel due to excess material

Signal For Start-up  Safe procedure: –Make sure crusher empty before another truck dumps –Area clear of personnel  Safe procedure: –Make sure crusher empty before another truck dumps –Area clear of personnel

Shut Down  Hazard: –Material left in crusher could jam  Hazard: –Material left in crusher could jam

Shut Down  Safe procedure: –Make sure material clears crusher & belts before shutting down  Safe procedure: –Make sure material clears crusher & belts before shutting down