In brief
Most accidents on sheet bending and cutting machines happen at three points: between the punch and die on the press brake, in the back gauge area behind the machine, and in front of the hold-downs and blade on the guillotine. A laser guarding system, a rear guard and a finger guard grille close off these areas; but multi-operator bending and handling large sheets require a separate work plan. Press brakes and guillotines undergo periodic inspection at least once a year under Annex III of the Work Equipment Regulation.
How do accidents happen in sheet bending and cutting?
Press brakes and guillotine shears are among the most common machines in metalworking and automotive supplier workshops in Bursa and the surrounding provinces. Both shape sheet metal with great force, and on both the operator's hand is right next to the work; press brake safety and guillotine safety therefore cover the working method as well as the guarding arrangement. Sheet bending accidents usually take the form of crushed or amputated fingers and hands, and face and body injuries from the sheet being flung.
The danger zones can be summarised by machine as follows:
| Danger zone | Press brake | Guillotine shear |
|---|---|---|
| Front point of operation | Between the punch (upper tool) and the lower die | Hold-downs and in front of the blade |
| Rear area | Between the moving back gauge fingers and the frame | Area where the cut part falls and the back gauge |
| Movement of the part | Sheet rising rapidly during bending | Feeding and slipping of large sheets |
| Maintenance and setting | Die change, back gauge adjustment | Blade change and clearance adjustment |
| Multi-operator work | Several operators and pedals at once | Position of the helper on long sheets |
Annex I, item 2.8 of the Regulation on Health and Safety Requirements for the Use of Work Equipment requires equipment with a risk of mechanical contact with moving parts to have guards or protective devices that prevent access to the danger zone or stop the movement before the danger zone is reached. The same item also requires that guards cannot easily be removed or rendered ineffective. For general guard types, see our article on machine guards.
Press brake safety: laser guarding and other front protection
On a press brake, the choice of front protection depends on the nature of the work. Because the operator holds small parts by hand while bending, a fixed guard often cannot be used. Common solutions are therefore:
- Laser-based guarding system: A transmitter and receiver mounted on the upper beam create a protective zone just below the punch tip and move with the beam. When the beam is interrupted, the closing stroke stops. Press brake laser guarding is one of the most suitable solutions for small-part bending where the hand has to be held close to the die.
- Light curtain: Creates a vertical detection zone in front of the machine. Because it can be triggered constantly in jobs where the operator holds the sheet, it is usually preferred for large parts or robotic cells.
- Two-hand control: Keeps both of the operator's hands on the controls; however, it cannot be used for jobs where the sheet has to be held by hand.
The safety requirements for hydraulic press brakes are defined in the TS EN 12622 standard, together with rules on the protective system and closing speed. The problems we see most often on site, however, are not technical but relate to use:
- No alignment after a die change: When a die of a different height is fitted, the laser system must be readjusted; an unadjusted system either stops constantly or does not protect at all.
- Working with the guarding disabled: In jobs such as "box bending", disabling the system becomes a habit. The override switch must be locked, and its use must depend on authorisation and be recorded.
- No daily test: At the start of each shift, the guarding system must be tested with a test piece and the result entered on the checklist.
Back gauge: the danger from behind
On modern press brakes, the back gauge consists of motor-driven fingers that change position for each bend. An employee who goes behind the machine to pick up a fallen part or to adjust the back gauge by hand can be crushed between the moving fingers and the frame, and at the same time enter the danger zone of a stroke started by the operator at the front.
Apply these measures for the rear area:
- The rear and sides of the machine are closed off with fixed guards, interlocked doors or a detection system; access to the rear area is controlled so that it stops the machine.
- If parts need to be collected from the rear, the part collection arrangement is moved to the front or side.
- Back gauge adjustment and die changes are carried out with the machine stopped and the energy isolated. Annex I, item 2.13 requires maintenance work to be carried out with the equipment switched off, the energy supply disconnected and all movement stopped. For lockout and tagout steps, see our article on LOTO lockout and tagout.
Multi-operator work and handling large sheets
Two or three people work together to bend long, heavy sheets. These jobs are the riskiest way of using a press brake, because the person pressing the pedal cannot always see where the helper's hand is.
Rules to follow in multi-operator bending:
- Separate controls for each operator: The machine must be set up so that each operator has their own foot pedal or control and the machine does not stroke until all controls are activated. Multi-operator work is never done with a single pedal.
- Visibility and position: Operators stand where they can see each other and the die area; no one stands in the direction in which the sheet rises during bending.
- Command sequence: Who starts the bend and with which verbal command is decided in advance.
The main danger in handling large sheets is the sheet rising. During bending, the part of the sheet that sticks out rises quickly; it can fling the holder's hand upwards or strike their face or chest. To prevent this, bend-following supports or sheet support arms are used, operators support the sheet from the side with an open palm, and nobody stands within the arc through which the sheet rises.
Guillotine shear safety: finger guarding and the rear area
Guillotine shear safety centres on two points: the hold-downs and the blade at the front, and the area where the cut part falls at the rear. In the cutting stroke, the hold-downs first press the sheet onto the table, then the blade comes down. A finger that gets under a hold-down is crushed; if it reaches the blade, it is cut.
- Guillotine finger guard: In front of the hold-downs there is a grille or screen with a gap that only lets the sheet through. The gap must be small enough to stop fingers reaching the hold-down and the blade. Raising the screen to cut thick sheet is the most common non-conformity.
- Rear area: The rear of the machine is closed off with a guard or a detection system; if cut parts are to be removed from the rear, the machine must be stopped.
- Feeding: Large sheets are fed with support arms or a ball transfer feed table; heavy sheets are moved with suitable lifting equipment.
- Blade change: Done with the energy isolated and locked out and with a blade handling fixture; cut-resistant gloves are worn against sharp edges.
On mechanical guillotines, clutch and brake failure creates the risk of an unintended second stroke. Clutch and brake maintenance on these machines must not be neglected. For similar risks on mechanical presses, see our article on press safety.
Periodic inspection, maintenance and machine age
Press brakes and guillotines are listed in Annex III of the Work Equipment Regulation; unless a standard or the manufacturer specifies a shorter period, periodic inspection is carried out at least once a year. The inspection is carried out by an engineer, technical teacher or technician registered on EKİPNET (the Ministry's register of authorised inspectors), and the contract is set up on ISG-KATİP (the Ministry's online OHS registration system) at least one day before the inspection. The person who maintains the equipment may not carry out its periodic inspection (Art. 14/A-2). We explain the intervals in our article on periodic inspection intervals for work equipment and how to read the report in how to read a periodic inspection report.
Periodic inspection does not replace daily checks. Set up both layers together:
| Check | Frequency | Who? |
|---|---|---|
| Testing the guarding system with a test piece | Start of every shift | Operator |
| Operation of the emergency stop buttons | Start of every shift | Operator |
| Finger guard screen and rear guard in place | Start of every shift | Operator |
| Hydraulic leaks, hoses and connections | Weekly | Maintenance |
| Maintenance and repairs entered in the maintenance log | After maintenance | Maintenance |
| Periodic inspection under Annex III | At least once a year | Authorised person registered on EKİPNET |
On machines with a maintenance log, maintenance work is entered in the log on the day it is done (Annex I, item 2.13.1). You can track periodic inspection dates with the OHS calendar tool. For the rules of the emergency stop arrangement, see our article on the emergency stop button.
Our article on bringing old machines without CE marking into compliance provides guidance on compliance work for older machines without CE marking. If you are buying a new press brake or guillotine, check which regulation the declaration of conformity refers to, because the Machinery Safety Regulation (EU 2023/1230) will largely enter into force on 20 January 2027; from that date the previous regulation based on 2006/42/EC will be the old regime. Details are in our article on the machinery safety regulation and CE marking.
As part of its OHS specialist services, Bursa Sistemer includes the guarding arrangement of sheet metal machines in the risk assessment, tracks the periodic inspection calendar arranged through our solution partners and follows up the closure of non-conformities in reports. Our general approach to the metal sector is on our metal and machinery page; first aid for limb injuries is covered in our article on first aid for amputation and crush injuries.
Frequently Asked Questions
Is a laser guarding system mandatory on a press brake?
The legislation does not require a particular type of guarding by name; it requires protection that prevents access to the danger zone or stops the movement before the zone is reached. On press brakes where small parts are bent by hand, laser-based guarding is a common solution that meets this requirement; the choice is made on the basis of the risk assessment.
How often are press brakes and guillotines periodically inspected?
At least once a year under Annex III of the Work Equipment Regulation; if a standard or the manufacturer specifies a shorter period, that period applies. The inspection is carried out by an authorised person registered on EKİPNET, and the person who carries out maintenance may not carry out the inspection.
What should be considered when two people work on a press brake?
Each operator must have their own control, and the machine must not stroke until all controls are activated. Operators must be able to see each other and the die, the bending command must be agreed in advance and nobody must stand in the direction in which the sheet rises.
Can the guillotine finger guard be raised for thick sheet?
It must not be raised. The guard must be adjustable to a gap that only lets the sheet through. If the guard has to be raised for thick sheet, the machine is not suitable for that job or the guard must be redesigned.
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Bursa SİSTEMER OSGB Technical Team — written from the field experience of our OHS specialists and workplace physicians. Legal information is valid as of the publication/update date; contact us for an assessment specific to your business.