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Common risk factors of rolling machine, how to control and improve?

Plate rolling machines come with inherent risks that need to be carefully managed to ensure operator safety and machine performance. Here are some common risk factors associated with plate rolling machines and methods to control and improve them:

Top 4 risk factors

Mechanical Hazards

Risk Factors: Pinch points, entanglement hazards, moving parts, hydraulic or pneumatic systems.
Control and Improvement: Implement machine guarding to protect operators from pinch points and moving parts. Ensure proper maintenance of hydraulic or pneumatic systems, including regular inspections, leak detection, and component replacements.

Material Handling

Risk Factors: Heavy plates, manual lifting, awkward postures.
Control and Improvement: Provide appropriate lifting equipment, such as cranes or forklifts, to handle heavy plates. Train operators in proper lifting techniques to minimize strain on their bodies. Consider the use of lifting aids like vacuum lifters or manipulators for improved ergonomics.

Manual Operation

Risk Factors: Manual feeding and positioning of the plate, hand tools, operator fatigue.
Control and Improvement: Use mechanical or automated feeding systems to reduce manual handling. Provide ergonomic workstations with adjustable heights and proper tooling to minimize strain and fatigue. Implement regular rest breaks to prevent operator fatigue.

Electrical Hazards

Risk Factors: Electrical components, wiring, improper grounding.
Control and Improvement: Ensure proper grounding of the machine and electrical components. Regularly inspect and maintain the electrical system, including wiring, switches, and control panels. Train operators on electrical safety procedures and the use of personal protective equipment (PPE) like insulated gloves.

Top 4 methods to control and improve

Operator Training and Competency

Risk Factors: Inadequate training, lack of knowledge on machine operation and safety procedures.
Control and Improvement: Provide comprehensive training programs for operators, covering machine operation, safety protocols, and emergency procedures. Regularly assess operator competency and provide refresher training as needed. Promote a culture of safety and encourage operators to report any safety concerns or incidents.

Risk Assessment and Safety Procedures

Risk Factors: Lack of risk assessment, absence of safety procedures and guidelines.
Control and Improvement: Conduct a thorough risk assessment of the plate rolling machine and its operation to identify potential hazards. Develop and implement safety procedures and guidelines based on the risk assessment findings. Regularly review and update safety protocols to ensure their effectiveness.

Maintenance and Inspections

Risk Factors: Neglected maintenance, worn-out components, lack of inspections.
Control and Improvement: Establish a regular maintenance schedule and perform routine inspections of the
plate rolling machine. Follow the manufacturer’s maintenance guidelines and recommendations. Replace worn-out or damaged components promptly to prevent accidents or machine failures.

Personal Protective Equipment (PPE)

Risk Factors: Insufficient or improper use of PPE.
Control and Improvement: Provide appropriate PPE, including safety glasses, gloves, hearing protection, and protective clothing. Train operators on the correct usage, maintenance, and storage of PPE. Regularly inspect PPE and replace damaged or worn-out items.

Key points of installation and use of Plate Rolling Machine

  1. The bending equipment is reliable grounding, lighting the safety voltage;
  2. Wedge, pin cannot give prominence to the surface;
  3. With the special tool with goggles.
  4. Parts installed firmly.
  5. Safety protection and protection device in time.
  6. Tail security bending device and material support frame.
  7. Selection of qualified grinding wheel, fitted with a reasonable card.
  8. Strengthen inspection, to eliminate the phenomenon of illegal wear and wear good labor protection supplies.

Three roll bending machines roll sheet metal to form curves.

When sheet metal is placed manually between the rollers, which must turn to secure the metal sheet, fixed or interlocked guards are impracticable. Plate metal thicker than approximately 6 mm will be placed by crane to prevent the operator from getting too close to the rollers, and to reduce the risk of manual handling injuries.


  • Trapping between rollers & metal
  • Trapping between turning rollers
  • Contact with sharp edges of metal
  • Noise
  • Slips, trips & falls
  • Entanglement from unexpected movement (during maintenance, cleaning & repairs)

Personal protective equipment (PPE)

  • Ear protection
  • Eye protection
  • Hand protection
  • Tasks
  • Task – Feed sheet metal through the rollers
  • Trapping between rollers & metal
  • Trapped hands and fingers
  • Crush injuries
  • ENSURE safety devices are in places, such as an emergency stop wire or kick plate.
  • ENSURE kick panels have a switch at each end.
  • FIT emergency stop devices on both sides of the machine.
  • HOLD workpieces back from the edge of the metal, allowing the metal to be fed into rollers without contact.
  • ONLY WEAR gloves if they are fingerless.
  • Sheet metal is usually placed by hand between the rollers, which turn together to pull the sheet through. As it passes between the rollers, the sheet curves to a diameter limited by the size of the rollers. The action that draws in a metal sheet can also draw in a hand. Finger ends of gloves can become entangled and draw fingers and hands into nips.

Task – Load & unload


Trapping between turning rollers & moving workpieces


  • Trapped hands
  • Crush injuries
  • Operation MUST only occur when the machine is in the “run” position.
  • COVER pedals to minimize the chance of accidental starts.
  • FIT emergency stop devices.
  • Contact with sharp edges of metal sheets


  • Cuts
  • WEAR fingerless gloves to protect palms.
  • Other (non-mechanical) hazards
  • Noise


  • Hearing damage or loss
  • REDUCE noise levels by isolating machines or enclosing within noise barriers.
  • ASSESS noise levels.
  • ARRANGE hearing screenings.
  • ALWAYS WEAR hearing protection.
  • A safe noise level over an eight-hour day is 85dB(A). A three-roll bending machine may exceed this noise intensity.


Slips, trips, and falls

  • HARM
  • Trapping
  • Cuts
  • Bruising
  • KEEP up-to-date housekeeping procedures.
  • KEEP the area around machines clear of slip and trip hazards.
  • Task – Maintenance, cleaning & repairs
  • Entanglement from unexpected movement


  • Trapped hands and fingers
  • Crush injuries
  • LOCK-OUT all power supplies before maintenance, cleaning, and repairs.
  • KEEP written safety procedures, and ARRANGE regular safety inspections by a competent person.
  • REMOVE or LOCK-OUT machines that fail inspection, and DO NOT USE until repaired or replaced.

Final Words

By addressing these common risk factors and implementing control measures, such as machine guarding, training programs, regular maintenance, and proper use of PPE, the safety and performance of plate rolling machines can be significantly improved, ensuring a safer working environment for operators.