Overview

What are these safety requirements and why are these being introduced & applied to our machines?

First issued in 2002, the CSA Z142 safety standard began to be applied to metal stamping and other presses. This standard in Canada and the ANSI B11 in the U.S are currently being reissued in 2009 and applications for other press types such as paver and block machines are now clearly in the scope of these safety requirements.

Both the ANSI B11.1&2 and the CSA Z142-09 safety standards are likely something most in the paver production industry have never even heard of until now, but all are well advised to learn more about it and ensure that operations comply. It was developed initially for the metal stamping industry, but is applicable to any operation such as paver and block machines based on their method of operation that forms, shears or blanks any material. It has been a coordinated effort between the two national regulatory authorities. Our industry has avoided scrutiny until this point, but there is a new focus on paver, block & slab machines.

So what are ANSI B11.1 & 2 / CSA Z142-09?

Straight from the document “The objective of this standard is to reduce the risk of injury due to hazards from the operation, maintenance and set-up, while working on, or adjacent to, a power press.” Some of the specific requirements applicable in this case are that press production equipment requires “Press Control reliability and redundancy, new training requirements and press type specific training.”

At this point there is not one concrete machine manufacturer that builds the machines or the controls that meet these new standards. Contact McCoy Equipment to find out how to ensure your plant meets these standards and your operations comply.

Upgrading

Who can assist us

J. McCoy Equipment, highly knowledgeable in paver production and processes for more than 20 years have assembled a top notch team with all of the required capabilities and direct experience in the upgrading of paver and block machines to meet these emerging safety requirements.

Working closely with Penmar Automation who have developed a specialized press control unit designed specifically to meet this safety monitoring mandate and Techserv TSI specialists in the complex and significant hydraulic upgrades required to ensure your paver and/or block machines are completely in compliance with the U.S and Canadian Safety Standards.

Established in 1991, Penmar Automation Inc. is a provider of technical services and proper safety upgrades to the wider Automation & Manufacturing Industry.

TECHSERV TSI. is an organization of technical specialists servicing the needs of domestic and international manufacturers. They have experience, knowledge and operations expertise in a broad range of industries, including automotive, electro-hydraulics, die casting, metal forming, robotics & heavy stamping. You can be assured of the highest standings of service in the industry.

As a team we will ensure all safety standard deficiencies are identified, the proper specifications for upgrade/retrofit are prepared and most importantly that these are then expeditiously completed to minimize any downtime required during the safety upgrade process, and keep the costs in line.

Systems Available

Paver, Block & Slab Machine Systems Available

  Single & multi-layer

  Mechanical & Hydraulic

  Retrofit Kits or Turnkey

Please inquire as to the status/requirements for the safety upgrade retrofit solution that will best meet your needs. Contact us today for more details.

Case studies

Staying Safe in Stittsville - A Block Production Safety Update

In the early 1960’s, what is today known as Permacon’s Stittsville operation, was originally founded by Tony Inderwick as Unit Precast. Located on a five acre site at 6775 Hazeldean Road in Stittsville, this location was acquired by Permacon in the mid 1980’s and operates one Besser V312 Block Machine capable of completing 4,000 block production cycles per day. The site currently has 17 employees, five of which recently celebrated their joint status of all having over 25 years of service with the firm, two of whom having 35 and 40 years of service respectively. So when, as a result of a 2008 safety ruling, the Ontario Ministry of Labor was on site for an accident investigation and it became apparent that the block machine and related equipment used for production did not meet current safety standards, management rapidly took action to identify and rectify these safety issues. It was at this time that Penmar Automation of Newmarket Ontario was then brought in as a result of a Professional Engineer’s review to assist with this process.

Specific deficiencies were identified with the guarding for the automated door by the block machine (CSA 432-04), safety interlocks etc. and most importantly the control system for the machine’s operation was not dual channel control reliable as required by the CSA Z142-09 power press safety standard.

The CSA Z142-09 safety standard is likely something most in the block production industry have never even heard of until now, but all are well advised to learn more about it and ensure that your operations comply. It was developed initially for the metal stamping industry, but is applicable to any operation such as block machines based on their method of operation that forms, shears or blanks any material.

In this case, the solution was to provide a Command Press control unit to the Permacon maintenance and electrical staff who then installed it themselves as part of the overall safety upgrades required on site to bring the equipment into compliance with the CSA Z142-09 Press Requirement and the Z432-04 Machine Guarding standards. In addition, there is also a requirement for “Operator competency verification and records of operator training” as well as a number of other “specific management responsibilities”. These are: “Employer shall ensure that power presses incorporate a total system of protection designed to ensure the safety of all people working within the press environment; Ensure compliance with Z142-09 standard; Any press modifications conform to standard” and that “Modifiers provide instructions and operating guideline changes.”

So why is this important to block and paver production operations? Well, if an accident were ever to occur with the equipment, not only could the company be subject to significant provincial fines should the investigation reveal any of the above safety deficiencies, but could also now even face heftier fines and criminal charges under federal Bill C-45. In fact in February 2008 the first conviction under Bill C-45 was a paving stone manufacturer in Quebec who plead guilty and was fined $110,000 including the 10% victim surcharge highlighting the need for this industry to address these safety issues. Specifically in this case had the system met the Z142-09 control monitoring requirements described above this fatality would have been avoided because the equipment would not have run with the light curtains disabled as was the case in this instance. This conviction also noted clearly the deficiency in operator training such that the worker likely didn’t even realize the fatal danger he was in.

Bill C-45 is an Act to amend the Criminal Code, (Criminal Liability of Organizations) which came into effect March 31st, 2004 and contains numerous provisions directly related to workplace and public safety.  Among others, this Bill includes the following provisions: imposition of legal duties on employers and those who direct work to take reasonable measures to protect employee and public safety; if this duty is carelessly disregarded and bodily harm or death results, an organization could be charged with criminal negligence; organizations may be found guilty of “negligence” if a “representative” is a party to the offence, or a “senior officer” (or officers) who is (are) responsible for the aspect of the organization’s activities that is relevant to the offence departs “markedly” from the standard of care to prevent a representative of the organization from being a party to the offence.

Most importantly: “every one who undertakes, or has  the authority, to direct how another person does work or performs a task is under a legal duty to take reasonable steps to prevent bodily harm to that person, or any other person, arising from that work or task.” The fine for a “summary conviction” has been increased from $25,000 to $100,000. There is no ceiling for fines on indictable or more serious offences. Fines of up to $1,000,000 are provided for breach of the Canada Labour Code. Jail sentences up to and including imprisonment for life are also possible. The above is applicable to anyone from a lead hand, foreperson or front line supervisor all the way up to the Directors of the company.

As there are only a handful of major producers of block machines in the marketplace, and none of these currently meet the Z142-02 standard as manufactured, it is almost a certainty that your operations currently do not comply unless you’ve had specific remedial modifications and the addition of reliable and redundant safety controls to your machine.

Concluding, it is important to keep up with the changes in safety codes and regulations that are applicable to your production equipment in order to protect not only your operations, but also your management, ultimately the business itself and most importantly the safety of your employees.