Forensic Engineers and Consultants

Archive: Workplace Injuries

Surprise Slip and Slides  

Falls were the number one cause of preventable non-fatal injuries and the number two cause of preventable deaths in the US in 2019 (CDC and NEISS data). Slip and falls occur when there is an unexpected loss of traction between a person’s foot and the walking surface.  Slip and falls are common and can occur in any setting where people walk, including homes, workplaces, and public areas. Slip and falls can result in serious injuries, particularly for older adults.

The human gait cycle consists of four phases: Read More

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HEY…Cover Up Please!

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Machine guards can be compared to the clothes we wear every day.  Indeed, they serve a very important purpose.  Imagine someone leaving their home on a fine, sunny morning wearing nothing but a smile.  Wonder how far they will get through the day before things start going poorly for this individual?

 

 

 

 

 

There will be more than a few raised eyebrows and blushes when he stops into the local Starbucks for his usual morning double-dipped and whipped, chocolaty chip with a touch of pumpkin spice cappuccino fix.  Good luck with that!  Probably going to leave disappointed, empty-handed, and likely wearing handcuffs.  This will be the beginning of a very long, very bad day for that individual.  Had he recognized the risks associated with this type of behavior, and then put forth a little effort to cover up, he would have prevented many unfavorable and possibly life-changing personal and legal problems from ever occurring!

And so it is with properly guarding a machine.  Machine safeguarding helps to protect workers from preventable injuries. Read More

One Small Step…

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Ladders…not a particularly exciting topic I’ll admit.  But hey, we need ladders to help us accomplish all kinds of tasks.  Most people have used at least one of the many types of ladders that are available today.  And the odds are probably pretty good that many of those users strayed outside the limits of safety a time or two while on a ladder.  It is amazing the risks some people will take to save some time or avoid the inconvenience of getting down to move the ladder into a safer position.  I wonder how many of those risks would be taken on a ladder if the users knew they were on camera.

Think about astronaut Neil Armstrong.  He travelled by rocket almost 239,000 miles through space and Read More

The Concepts of Hazard, Risk, and Harm in Machine Safeguarding

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Hazard, risk, and harm are terms that are used in the world of machine safeguarding.   How do these words shape the concept of machine safeguarding? Let’s look a little deeper….

Hazard, which Merriam-Webster defines as a noun, lists its first meaning as a source of danger.

1: a source of danger

2a: the effect of unpredictable and unanalyzable forces in determining events : CHANCE, RISK

  b:  a chance event : ACCIDENT  Read More

Conveyor Backstops: Sometimes One Isn’t Enough, Part 2

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This is the second in a two-part blog series about conveying equipment that severely injured a worker at a mine. In case you missed it, click here to read Part 1 where I describe the incident and the mining equipment. In this part, I will discuss my engineering analysis of the incident and the machinery involved and share the conclusions I reached.

The injured miner was a front-end loader operator. He was not a maintenance worker. He simply responded to a radio request for help with the conveyor. Power to the electric conveyor motors was locked out, but none of the maintenance workers did anything to lock out or block the hazardous gravitational potential energy in the heavy load of stone on the belt. Read More

What’s Behind That CE Mark Part Three, Machine Guard Requirements

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In the first blog in this series, we discussed the story behind the CE mark, the Machinery Directive, and the associated requirements regarding the design, production, and sale of machinery bearing the mark. The second blog discussed a cornerstone of safer machine design, the risk assessment. This installment will discuss another crucial piece of the safety puzzle, machine guard design. Read More

Ammonia

Ammonia – The Good, The Bad, The Smelly… Part One

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Ammonia is a compound consisting of one nitrogen atom and three hydrogen atoms and is denoted by the formula NH3. Its boiling point is -28°F at atmospheric pressure, so unless it is under pressure, it is gaseous at room temperatures. Therefore, pure ammonia is typically stored under pressure in a liquid form. Household ammonia is only 5-10% NH3, the remaining 90-95% is water. Ammonia is extremely soluble in water. It is often depicted  like this: Read More

Unguarded Shear Point on Force Tester Amputates Worker’s Finger

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A worker was injured while testing gas springs similar to the type that hold the hatchback of an SUV open. The hazard that injured the worker was an unguarded shear point. The tester contained a mounting plate that was raised and lowered by a pneumatic cylinder.

The pneumatic cylinder lowered the mounting plate while the worker’s fingers were in the hazardous, unguarded shear point. Read More

Defective Vertical Baler Causes Serious Crush Injury to Operator’s Arm

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I recently worked on an interesting case involving a box baler. An employee of a butcher shop put some empty cardboard boxes in a vertical box baler and pushed the control switch to compact the boxes. After the 30 by 60 inch platen weighing 851 pounds returned to its raised position, the employee reached into the open space above the bottom door on the baler and began to clear cardboard from the bale tie slots in the bottom of the raised platen. Suddenly, and without warning, the steel pin attaching the platen to the raised hydraulic cylinder rod failed. The heavy steel platen fell and crushed his arm which was outstretched over the baler door into the compaction space.

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Injury Involving a Capstan Winch

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A capstan winch uses a mechanically powered rotating cylinder, called a capstan, to apply pulling force through a rope. When the rope is looped around the rotating capstan and tightened, friction between the rope and capstan allows the winch to apply force to pull a load. A typical capstan winch is shown in Figure 1 below. Read More

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