Introduction: Elevating Machine Safety in Construction Supply Manufacturing
Atkore is a North American powerhouse in the construction supply industry, known for its electrical raceway and mechanical product systems. As a leading producer of PVC conduit used in residential, commercial, and industrial applications, Atkore's high-speed extrusion facilities play a crucial role in supporting electrical infrastructure nationwide.
However, with productivity comes risk. Atkore's PVC manufacturing lines include extrusion, cooling, puller, and cutting systems that expose operators to high heat, rotating motion, cutting blades, and pneumatic energy. These hazards present serious challenges to OSHA 1910.212 compliance and ANSI B11.19 safety standards.
Atkore partnered with PowerSafe Automation to develop a scalable machine guarding solution that met strict safety standards while supporting the operational needs of high-volume, lean manufacturing lines. The result? A customized, plant-wide machine guarding deployment that now serves as a model for other facilities in the construction supplies sector.
Industry Challenge: Risk vs. Runtime in PVC Extrusion
PVC conduit manufacturing involves continuous processes with minimal downtime. Extrusion machines operate under high temperature and pressure, downstream pullers drive product through cooling tanks, and automatic cutters trim the conduit to length. These processes are critical to throughput but create:
- Exposure to hot surfaces and extrusion feed zones
- Pinch points at pullers and conveyor transitions
- Sharp, fast-moving guillotine or flywheel cutters
- Pneumatic accumulator and bundler hazards
Atkore’s challenge was typical of many construction material manufacturers:
- Aging Guarding Systems: Many older machines lacked interlocks, visibility panels, or hinged access points.
- Lean Workflow Requirements: Changeovers and maintenance had to be fast. Traditional guarding slowed operations.
- Multi-Facility Standardization: With facilities across the U.S., Atkore needed repeatable, code-compliant guarding that could be implemented plant-wide.
PowerSafe Automation was selected to lead the engineering, fabrication, and installation of a custom machine guarding solution that solved for all three challenges.
The PowerSafe Solution: Engineered Safety with Turnkey Support
1. Onsite Risk Assessment Using RRPP Framework
PowerSafe’s safety engineering team conducted onsite assessments at multiple Atkore facilities using its proprietary RRPP (Recognize, Rank, Prioritize, Plan) method. Each machine hazard was scored for severity, exposure, frequency, and avoidance, yielding a prioritized guarding plan.
Key equipment assessed included:
- PVC extruders with heated barrel access
- Chain pullers and automated feed conveyors.
- High-speed cutting systems
- Cooling tank transitions
- Pneumatic accumulators and bundlers
2. Tailored Guarding Designs with T-Slotted Aluminum Framing
PowerSafe designed modular guarding using aluminum T-slot framing to meet Atkore’s requirements:
- Custom Fit: Each guard conformed to specific machine dimensions.
- Quick Access: Hinged doors, removable panels, and tool-free latches enabled fast maintenance.
- Clear Visibility: Lexan polycarbonate panels provided full line-of-sight without compromising safety.
- Thermal Management: Perforated steel guards were used near heat zones to allow ventilation.
- Durability: Panels were powder-coated and reinforced to withstand harsh plant environments.
3. Integrated Safety Controls and Interlocks
Where possible, guarding included:
- Non-contact magnetic interlocks with coded RFID sensors
- Trapped key systems for LOTO compliance.
- Safety relays integrated into Atkore’s existing PLCs.
- Visual indicators for open panel status
This not only protected operators but ensured that machinery could not operate while access doors were open, or panels were removed.
4. Pre-Assembled Kits and Field Installation
PowerSafe prefabricated all guards in-house and delivered labeled, pre-assembled kits to minimize installation time. Guarding was installed during scheduled maintenance windows to prevent production downtime. PowerSafe also provided:
- Assembly guides and panel layout maps
- Floor anchor templates and cable routing plans
- Field crew support during installation
Outcomes: Safer Workspaces, Leaner Operations
OSHA and ANSI Compliance
Every guarding assembly met or exceeded:
- OSHA 1910.212 General Machine Guarding
- ANSI B11.19 Performance Requirements for Safeguarding
- ISO 13849-1 Safety-Related Control Systems
Atkore now has audit-ready documentation to support safety inspections and insurance evaluations.
No Disruption to Production
Thanks to weekend and maintenance-window installs, zero unplanned downtime occurred during the entire rollout. PowerSafe’s just-in-time delivery minimized plant floor congestion.
Operator Visibility and Ergonomics
Guarding improved visual inspection and intervention without needing to remove panels. Operators no longer had to choose between safety and visibility.
Standardization Across Facilities
With documented part numbers and CAD drawings, Atkore can replicate and scale the same guarding designs to multiple extrusion sites across North America.
SEO Insight: Why Tailored Machine Guarding Matters for Construction Supply Manufacturing
Manufacturers of construction materials like PVC, conduit, steel pipe, and vinyl siding face one of the highest rates of machine-related injuries due to high-speed equipment, sharp tools, and thermal hazards. Investing in tailored machine guarding solutions is not just about compliance—it directly reduces:
- Lost-time injuries (LTIs)
- Workers’ compensation claims
- Downtime due to safety incidents
- Risk of OSHA citations or fines
Key phrase for search optimization: Tailored Custom Machine Guarding for PVC and Conduit Manufacturing
When facilities use a one-size-fits-all guarding solution, they often sacrifice accessibility, create operator frustration, and invite unsafe workarounds. But a tailored approach engineered for the specific risks of extrusion lines and puller/cutter systems allows manufacturers to:
- Improve operator safety culture.
- Meet safety regulations with confidence.
- Maintain productivity and lean practices.
- Standardize safety across facilities.
For companies producing construction materials, custom guarding is no longer optional—it is a core part of long-term risk management.
Testimonial from Atkore’s EHS Team
"PowerSafe wasn’t just a vendor. They were a partner in helping us engineer safety into every piece of the process. The guarding fit our lines, did not slow us down, and helped our team feel more confident on the floor. We are already planning to roll this out across other facilities." — Regional EHS Director, Atkore
Conclusion: From Reactive to Proactive Safety
Atkore’s investment in tailored machine guarding has transformed its PVC manufacturing lines from a high-risk environment into a model of proactive safety and operational efficiency. With custom-designed, modular, and scalable guarding, the company not only meets compliance obligations but builds trust with its workforce.
As manufacturers in the construction supply industry seek to modernize their operations, prevent injuries, and avoid OSHA citations, the message is clear: Do not guard for the audit. Guard for the operator.
