DEPARTMENT OF LICENSING AND REGULATORY AFFAIRS

DIRECTOR'S OFFICE

GENERAL INDUSTRY SAFETY AND HEALTH STANDARD

(By authority conferred on the director of the department of licensing and regulatory

affairs by sections 16 and 21 of the Michigan occupational safety and health act, 1974 PA

154, MCL 408.1016 and 408.1021, and Executive Reorganization Order Nos. 1996-2,

2003-1, 2008-4, and 2011-4, MCL 445.2001, 445.2011, 445.2025, and 445.2030)

PART 42. FORGING

GENERAL PROVISIONS

R 408.14201 Scope.

Rule 4201. This part provides safety for life, limb, and health in or about places

of employment and applies to all classes of power-forging machinery both for drop

forging and flat-die forging, including steam hammers, pneumatic hammers,

mechanically operated hammers, forging presses, forging rolls, trimming presses,

bulldozers, upsetting machines, bolt-heading and rivet-making machines and power

shears, and incidental operations and equipment in connection with such machinery.

Excluded are cold forging operations.

History: 1979 AC.

R 408.14203 Definitions; A to C.

Rule 4203. (1) "Aisle" means a path of travel for vehicles and employees and

which is not used for work and storage space.

(2) "Board drop hammer" means a hammer equipped with boards attached to the

ram which when propelled by motor driven friction rolls raises the ram and

attachments.

(3) "Cylinder head" means a cover attachment for the top of a steam cylinder.

History: 1979 AC.

R 408.14204 Definitions; F, G.

Rule 4204. (1) "Forging press" means a mechanically or hydraulically operated

press using closed or flat dies.

(2) "Forging rolls (reducing rolls)" means rolls used as equipment for forging or

swaging operations. Forging rolls are required essentially for reducing short, thick

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stock sections into long, slender sections and to perform or reduce cross-sectional

areas of billets before the finished forging operation.

(3) "Guide bolt" means a bolt which passes through the hammer columns and

secures the ram guides in the pocket.

History: 1979 AC; 1989 AACS.

R 408.14205 Definitions; H to P.

Rule 4205. (1) "Hammer" means a machine designed to shape forgings by

means of impact between dies. The force of the impact is by gravity or power

supplied by steam, air or mechanical means.

(2) "Mechanical hammer" means a gravity hammer which uses hydraulic or

mechanical devices, such as friction rolls with boards, belts, or ropes to raise the ram

and attachments.

(3) "Point of operation" means the area of a machine, die, or tool where material is

actually worked.

(4) "Power shear" means a machine equipped with opposing shear blades and

which cuts bar stock.

History: 1979 AC.

R 408.14207 Definitions; R, S.

Rule 4207. (1) "Rod gland" means a sleeve at the bottom of a cylinder through

which a piston rod passes.

(2) "Safety factor" means the ratio of the breaking strength of a piece of material or

object to the actual safe load or working stress when in use.

(3) "Steam or pneumatic hammer" means a hammer using steam or air to

provide energy in a cylinder to raise the hammer for a gravity drop and in case of a

double action hammer to increase the force of the impact on the forging.

History: 1979 AC.

R 408.14208 Definitions; T to W.

Rule 4208. (1) "Tie plate" means a plate located and attached to the upper

structure of hammer columns and on which the steam cylinder is mounted.

(2) "Trained and authorized" means to have received instructions regarding

specified duties and to have permission to perform those duties.

(3) "Trim press" means a class of auxiliary forging equipment which removes

flash or excess metal from a forging.

(4) "Upsetting machine" means a horizontal forging machine employing a set of

gripper dies that holds stock while the ram or header slide forces the stock into shape

and size.

(5) "Walkaway" means a path of travel for foot traffic only.

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History: 1979 AC.

R 408.14221 Rescinded.

History: 1979 AC; 1997 AACS.

R 408.14222 Aisles.

Rule 4222. An aisle for vehicular traffic shall be not less than the width of the

widest vehicle or load plus 3 feet. An aisle shall be outlined by marking.

History: 1979 AC.

R 408.14223 Platforms.

Rule 4223. A platform used on the floor in front of a machine shall be designed

to hold the weight imposed on it without creating a tripping hazard.

History: 1979 AC.

R 408.14224 Lighting and controls.

Rule 4224. (1) Machinery and equipment shall be provided with a minimum of 15

footcandles light intensity to fall upon the general area. When natural light is

insufficient, artificial light shall be provided. Direct or reflected glare and shadows,

including moving shadows, should be avoided.

(2) A manually operated valve or switch for power forging equipment shall be

identified as to function and accessible to the operator.

History: 1979 AC.

R 408.14225 Rescinded.

History: 1979 AC; 1997 AACS.

R 408.14226 Use of lead.

Rule 4226. The following safety requirements apply to lead casts or other use

of lead in a forge shop or die shop:

(a) Thermostatic control of heating elements shall be provided to maintain

melting temperature at not more than 750 degrees Fahrenheit.

(b) A covered container shall be provided to store dross skimmings.

(c) Equipment shall be kept clean, particularly from accumulations of lead oxide.

(d) A sign shall be posted in the work area prohibiting eating in the area and

calling attention to dangers of oral ingestion of lead dust from hands and clothing.

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History: 1979 AC.

R 408.14227 Scale removers, oil swabs, and tongs.

Rule 4227. (1) If an oil swab, scale brush, or other device is required to remove

scale, it shall be long enough to enable the employee to perform the job without placing

his hands within the point of operation.

(2) Tongs shall be of sufficient length to clear the body of the worker in case of

kickback, and shall not have sharp handle ends. The worker should be instructed in

the proper body position when using tongs. Tongs should be checked periodically to

see that they remain at the proper hardness level for the job. When rings or

equivalent devices for locking tongs are used, they should be inspected periodically

to ensure safe condition.

History: 1979 AC.

R 408.14231 Rescinded.

History: 1979 AC; 2013 AACS.

R 408.14232 Personal protective equipment.

Rule 4232. (1) Protective goggles or spectacles shall be provided to, and used

by, all employees where a face and eye hazard exists.

Protective goggles and

spectacles shall comply with the requirements of general industry safety standard,

Part 33. Personal Protective Equipment, being R 408.13301 et seq. of the Michigan

Administrative Code.

(2) Head protection shall be provided to, and used by, all employees where a

head hazard exists. Head protection shall comply with the requirements of general

industry safety standard, Part 33. Personal Protective Equipment, being R

408.13301 et seq. of the Michigan Administrative Code.

(3) Foot or toe protection shall be provided to, and used by, all employees in

accordance with general industry safety standard, Part 33.

Personal Protective Equipment, being R 408.13301 et seq. of the Michigan

Administrative Code, where a foot or toe hazard exists.

(4) Other types of personal protective equipment, such as aprons, spats, sleeves,

and specialty gloves other than lightweight cotton or similar types of gloves, shall be

provided to, and used by, employees when such personal protective equipment is

required for the protection of the employee from hazards.

History: 1979 AC; 1989 AACS.

R 408.14241 Guards, hammers, and forge presses.

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Rule 4241. (1) The portion of a treadle at the rear of a hammer shall be guarded so

that scrap or other material cannot collect below this portion of the treadle and prevent it

from returning to normal position.

(2) A treadle shall be blocked or otherwise secured during the time an employee

is exposed under the ram or between the dies.

(3) A scale guard constructed of not less than 20 gauge sheet steel or equivalent

material shall be provided at the back of a hammer, so arranged as to stop flying objects

and anchored or secured so that it cannot tip or fall.

(4) A foot operated device, such as a treadle, pedal, bar, valve, or switch, shall

be substantially and effectively protected from unintended operation.

History: 1979 AC.

HAMMER AND FORGE PRESSES

R 408.14242 Hammer installation.

Rule 4242. (1) A hammer shall be installed on or anchored to a foundation

of such strength as to support the imposed weight and normal work stress.

(2) A press shall be installed in a manner that it will remain in position or it

shall be anchored to a foundation of such strength as to support the imposed weight

and normal work stress.

History: 1979 AC.

R 408.14243 Ram props and blocks.

Rule 4243. A ram prop or block shall be provided and used at each hammer when

dies are changed or repaired. The prop or block shall have a handle on the side. One of

the following shall be used:

(a) A wooden ram prop or block of hardwood and complying with not less than

the specifications of table 1. The ends shall be square.

(b) A steel ram prop of not less than 2 1/2-inch outside diameter by 2-inch

inside diameter, or a structural shape of equal strength, with squared ends.

(c) Other material which shall be of equal or greater strength as required for

steel in subdivision (b).

Figure for 408.14243

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History: 1979 AC.

R 408.14244 Hammer die keys.

Rule 4244. (1) A hammer die key and shims shall be made from a grade of

material which does not crack or splinter when treated. A die key shall project not

more than 3 inches in front or in back of the ram or die.

(2) A head of a key shall be kept free of mushrooming and splitting by grinding

off any flaring.

(3) A head of a manual key driver shall be kept free of mushrooming by grinding

or machining. A cutting torch shall never be used for this. A driver shall be

suspended from a securely fastened beam with chain or cable of sufficient size to

handle the weight of the driver plus a safety factor of 5. Chain, cable and fasteners

shall be kept free of twisted, bent or elongated links. A driver shall be made of steel

that will not chip on impact.

(4) A pneumatic key driver is recommended. The driver shall be made of steel

that will not chip on impact.

History: 1979 AC.

R 408.14245 Hammer cylinder heads and fasteners.

Rule 4245. Parts, such as, but not limited to, a cylinder head and fasteners for a

cylinder head, glands, tie plates and guide bolts, which are subject to failure shall be

secured by use of a safety cable strung to them.

History: 1979 AC.

R 408.14246 Steam and pneumatic hammers.

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Rule 4246. (1) A steam or air hammer shall be equipped with a functional safety cylinder

head to act as a cushion if the piston rod breaks or pulls out of the ram.

(2) A steam hammer shall be provided with a quick access emergency shut-off valve

identified by name or color in the supply, sometimes called admission, pipeline at a

location within reach of the operator. This valve shall be closed and locked in the “off”

position while the hammer is being adjusted, repaired, or serviced, or when the die are

being changed, except where necessary to move the ram.

(3) If the steam hammer cylinder is constructed without a self-draining arrangement, a

drain cock shall be provided which shall be piped to a sump or drain pipe.

(4) A pneumatic hammer shall have a drain cock on the main head cylinder and on the

clamp cylinder, if a clamp cylinder is provided.

(5) Steam or air pressure at the hammer shall be no higher than that for which the

hammer is designed. A pressure regulator and safety valve at the source of power or at

the equipment, whichever is applicable, shall be used to insure this.

(6) A steam pipe shall be covered where exposed to contact. Pipe supports or other

effective means shall be provided to prevent failure from vibration, expansion, or

contraction.

(7) Steam or air piping shall be as prescribed in ANSI B31.1.0-1967, Power piping, with

addenda issued before April 28, 1971, which is incorporated herein by reference and may

be inspected at the Lansing office of the Department of Licensing and Regulatory Affairs.

This standard may be purchased from IHS Global, 15 Inverness Way East, Englewood,

Colorado, 80112, USA, telephone number: 1-800-854-7179 or via the internet at website:

http://global.ihs.com, at a cost as of the time of adoption of these rules of $96.00 each.

(8) Where it is necessary to service a steam cylinder, a fixed platform, as prescribed in R

408.14249(2), shall be provided, or the employee shall wear a safety belt and lanyard,

with the lanyard secured to the hammer or a structural member.

History: 1979 AC; 2013 AACS.

R 408.14247 Mechanically operated hammers and forging presses.

Rule 4247. (1) A mechanically operated hammer or forging press shall be

provided with a means for disconnecting the power. Acceptable methods include the

following:

(a) A disconnect switch ahead of the starter on the primary line with provision

for locking and within reach from the floor. Power shall be locked off when the

machine is being repaired or serviced.

(b) A tight and loose pulley on a countershaft, with a belt shifter, with a means

to lock it in the "off" position. The belt shifter shall be within easy reach of the

operator.

(c) A clutch or drive pulley, with a clutch handle, with a means to lock it in the "off"

position. The clutch handle shall be within easy reach of the operator.

(2) Springs suspending the ram in a mechanically operated hammer shall be

enclosed or restrained from flying in case of breakage.

History: 1979 AC.

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R 408.14248 Point of operation devices.

Rule 4248. Effective August 31, 1974, the following shall pertain

mechanically operated hammer used for cold re-strike operations:

to

a

(a) Where only 1 hand is used for holding the material, a safety stop, dog or catch

shall be provided to prevent the ram from descending until this device has been

released and is held out of the way by the other hand, or a hand lever instead of a

foot treadle shall be provided for tripping the hammer.

(b) On a hammer where neither hand is used for holding the material, there shall

be provided a point of operation device that restrains the operator from inadvertently

reaching into the point of operation or which automatically withdraws the operator's

hands if they are within the point of operation as the dies close, or a tripping lever or

safety stop or both that will require concurrent use of both hands to trip the hammer.

History: 1979 AC.

R 408.14249 Board drop hammers.

Rule 4249. (1) On a board drop hammer a guard constructed of 20 gauge sheet steel

or stronger must be provided around the board above the rolls to prevent the board from

falling if the board breaks or comes loose from the ram.

(2) Where work must be done at or near the rolls of a board hammer, a fixed or

portable platform equipped with a guardrail system must be provided and used in

compliance with General Industry Safety and Health Standard Part 2. “Walking-Working

Surfaces,” being R 408.10201 to R 408.10241 of the Michigan Administrative Code.

(3) Roll release levers and front friction rods on a board hammer must be prevented

from falling by being secured to the hammer frame by cable, chain or an equally effective

means.

History: 1979 AC; 2019 AACS.

R 408.14251 Forging presses.

Rule 4251. (1) Forging press operating valves shall be located so that the

operator will have a clear and unobstructed view of the press when standing in the

usual operation position. If this arrangement

is impossible, a mirror shall be

installed in front of the operator to assist him in obtaining a full view of the press.

(2) When dies are being changed or maintenance is being performed on a press,

the following shall be accomplished:

(a) The energy source to a mechanical press shall be locked out, and the flywheel

shall be at rest before work begins.

(b) The hydraulic pumps and power apparatus of the hydraulic press shall be locked

out.

(c) Blocking shall be provided and used to prevent the ram from dropping.

The material shall equal or exceed specifications in table 1.

Die design shall take into consideration the need for a flat spot for the block.

(3) Location of steam, air, or water headers and scale or splash aprons shall give

the operator sufficient clearance at the front of the forging press for any upward or

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downward movement of the tongs without creation of a pinch point between these

facilities and the tongs.

(4) A hot forging press shall be equipped with a scale guard, as prescribed in

R 408.14241(3).

(5) A forging press shall be provided with a positive means for retaining a

piston and head assembly inside the counterbalance cylinder in case of failure or

breakage of the piston and rod assembly.

(6) An electrical motor shall be provided with a disconnect switch, as prescribed

in R 408.14247(1). A hydraulic forging press shall be equipped with a positive type

lockout disconnecting switch or valve.

(7) Fire resistant fluids shall be used in a hydraulic press forming hot work.

(8) Die bolts shall not be worn or damaged, and shall be long enough to permit

being threaded into die bolt holes a distance not less than 1 1/2 times the diameter of

the bolt. Washers shall not be used in multiple to compensate for excessive lengths of

bolts.

(9) A mechanical foot pedal or foot switch shall be covered on both sides and

top with a substantial guard to prevent accidental tripping. The guard shall have rolled,

broad, or covered edges to prevent injury or discomfort. The mechanical foot pedal

shall be mounted to a press leg or anchored to the floor.

History: 1979 AC.

R 408.14252 Inspection.

Rule 4252. (1) Daily visual observation, without dismantling, shall be made of a

forging hammer and forge press to insure the safe condition of bolts, screws, keys,

valves, and all parts of treadles and clutches and other operating mechanisms that

might become loose by vibration.

(2) A periodic and regular maintenance safety inspection shall be made of forging

machinery and equipment, including guards and point of operation protection

devices by a trained and authorized employee.

(3) A record shall be made and maintained to show the date of inspection,

equipment number and condition found.

History: 1979 AC.

OTHER MACHINES

R 408.14261 Trim presses.

Rule 4261. (1) A trim press shall be provided with a main disconnect switch as

prescribed in R 408.14247(1).

(2) A trim press shall be provided with a safety block or prop as prescribed in

R 408.14243. Die design shall take into consideration and provide a suitable flat area

in the die for locating and using blocking material.

(3) A trim press shall be fed by devices as prescribed in R 408.14251(10).

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History: 1979 AC.

R 408.14263 Bulldozers.

Rule 4263. A guard shall be attached to the side of the moving head of a bulldozer and

shall extend past the stationary head to prevent persons from stepping between the dies,

or another method may be used which offers equal protection.

History: 1979 AC; 2013 AACS.

R 408.14265 Bolt heading and rivet-making machines.

Rule 4265. (1) A treadle (pedal) of a bolt heading or rivet-making machine

shall be guarded as prescribed in R 408.14251(9).

(2) A bolt header or rivet-making machine shall be equipped with a positive-

type lockout device as prescribed in R 408.14247(1).

(3) A screen shield shall be installed across point-of-operation on a bolt heading

or rivet-making machine to protect against flying pieces.

(4) Tension or relief springs on a bolt heading or rivet-making machine shall be

guarded.

(5) Safety blocks as prescribed in R 408.14243 shall be used when required

while working on, removing, or setting dies.

History: 1979 AC.

R 408.14267 Power shears.

Rule 4267. (1) The maximum size and specification of material being sheared on a power

shear, as recommended by the manufacturer of the shear, shall not be exceeded.

(2) Effective point-of-operation guarding shall be provided at both the feeding end and

discharge end of a power shear.

History: 1979 AC; 2013 AACS.

R 408.14268 Material-handling equipment.

Rule 4268. Material-handling equipment shall be of such capacity and size as to

safely handle the imposed load of the dies and containers.

History: 1979 AC.

R 408.14269 Tumbling barrels and shot blasts.

Rule 4269. (1) A tumbling barrel shall have all of the following:

(a) Have fittings to the barrel dust-tight or the barrel enclosed in a booth with an

exhaust system as approved by the state department of licensing and regulatory affairs.

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(b) Be locked in place while being loaded or unloaded.

(c) Have an interlocked barrier across the front before it can be started.

(2) A shot blast cleaning chamber shall have doors, curtains including silhouettes, or

guards to protect the operator.

History: 1979 AC; 2013 AACS.

R 408.14271 Upsetting machines.

Rule 4271. (1) An upsetter pedal (treadle) shall be guarded as prescribed in

R 408.14251(9).

(2) A shut-off valve or safety switch for service equipment on an upsetter,

such as air lines, electric lines and water and oil lines, shall be located conveniently for

the operator, and each shall be distinctly marked for ease of identification.

(3) A positive type lockout device for disconnecting the power to the upsetter

shall be provided as prescribed in R 408.14247(1).

(4) An upsetting machine shall be installed so that it will remain on its

foundation.

History: 1979 AC.

R 408.14273 Billet heating furnaces.

Rule 4273. (1) A billet heating furnace shall be equipped with an automatic valve on the

main fuel line which will shut off in case of electrical or fuel supply failure.

(2) Radiant heat from a billet furnace shall be controlled by 1 or more of the following

methods:

(a) Reflective shields of aluminum or materials of equal reflectivity.

(b) Controlled openings.

(c) Evaporative cooling.

(d) Water jackets.

(e) Chain curtains.

(3) An exhaust system shall be provided as prescribed by the state department of

licensing and regulatory affairs.

History: 1979 AC; 2013 AACS.

Editor's Note: An obvious error in R 408.14273 was corrected at the request of the promulgating

agency, pursuant to Section 56 of 1969 PA 306, as amended by 2000 PA 262, MCL 24.256. The rule

containing the error was published in Annual Administrative Code, 2013. The memorandum requesting the

correction was published in Michigan Register, 2016 MR 10.

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