A contractor was lucky to escape serious head injuries whilst maintenance work was being carried out on a conveyor belt system, a metal return roller guard fell 4m and hit his hard hat.
The contractor was standing under the incline conveyor belt system as he pulled the old conveyor belt through the system. During this operation an original return roller nip guard was dislodged. Investigation showed that it was designed so that it hung over the roller shaft and was only held in place by the belt and gravity.
The guard weighing circa 8kg fell 4m and hit the contractor on the centre of his hard hat. Fortunately, the contractor suffered only neck and muscle strain and was able to continue working after a short period.
This design may exist on conveyor systems on other sites.