Overhead conveyors keep floors free, but they bring their own hazards: falling objects, pinch points, moving loads at head height and maintenance work at height. This guide lists the main hazards, the standards that apply and a practical safety checklist.
Main hazards
- Falling products or parts where the conveyor passes over walkways and work areas
- Pinch and shear points at chains, sprockets, drives, take-ups, switches and stops
- Moving carriers at head height in load and unload areas
- Unexpected start-up during maintenance
- Lifts and drop sections lowering loads into work areas
- Work at height during inspection and maintenance
Standards that apply
| Standard | Scope |
|---|---|
| ISO 12100 | General principles for machinery risk assessment and risk reduction |
| EN 619 | European safety requirements for conveyors handling unit loads |
| ASME B20.1 | Safety standard for conveyors and related equipment, widely used in North America |
| Machinery Directive / Regulation (EU) | CE marking requirements in the European Union |
| OSHA 29 CFR 1910.147 | Control of hazardous energy (lockout/tagout) in the United States |
Check which standards and local regulations apply at your site; this list is not exhaustive.
Design measures
| Hazard | Typical measures |
|---|---|
| Falling objects | Guards or nets under the conveyor over walkways and work areas |
| Pinch points | Fixed guards at drives, take-ups and transfers; covered chain |
| Moving carriers | Marked zones, light curtains or gates at stations |
| Lifts | Safety catches, fall protection, guarded lowering zones |
| Unexpected start | Emergency stops, start-up warnings, lockout points |
| Work at height | Maintenance platforms, access points and fall protection |
Controls and safety circuits
Emergency stops must be reachable along the line, especially at stations. Safety circuits for gates, light curtains and lifts should be designed to the required performance level from the risk assessment. Warning signals before automatic start-up help people clear the area.
Daily and periodic safety checks
- Test emergency stops and gate interlocks
- Check guards and nets for damage or missing parts
- Inspect hooks and carriers for cracks and wear
- Verify lift safety catches and brakes
- Confirm lockout points are labelled and locks are available
- Keep walkways under the conveyor clear and marked
Combine these with the routine tasks in our maintenance checklist.
Training
Operators should know the emergency stops, safe zones and what to do when a carrier jams. Maintenance staff need training in lockout, work at height and the specific hazards of drives, take-ups and lifts.
HITREE designs safety into every power and free and EMS system, from risk assessment to guarding and control. Contact us to discuss your requirements.
How to run a conveyor risk assessment
- Define the limits of the conveyor: route, stations, operating modes and maintenance tasks.
- Identify hazards at every point along the route and in every operating mode.
- Estimate the risk: how severe, how often people are exposed, how likely.
- Reduce the risk by design first, then guarding and safety devices, then information and training.
- Document the result and review it after every change to the line.
This follows the method of ISO 12100 and is the basis for overhead conveyor safety design and CE documentation.
Safety in load and unload stations
Load and unload stations are where people and moving carriers meet most often. Good practice includes stopping carriers during loading, clear floor markings, controls that require the operator to release the carrier, and ergonomic heights to avoid reaching into the path of moving carriers.
