According to OSHA 29 CFR 1910.217, "The employer shall provide and enforce the use of safety blocks for use whenever dies are being adjusted or repaired in the press." They are not required during die setting unless die blocks are included in your die setting procedure. They also satisfy the lockout/tagout requirements for isolating mechanical energy.
Die safety blocks are placed between the die punch and holder with the machine stroke up. They are rated to support a static load. The static load represents the combined weight of the press ram, ram components (ram-adjust assembly and connection rod[s] or pitman arm[s]), and the upper die.
In some applications, as many as four safety blocks may be required. This is determined by the size of the press bed and the weight the blocks must support. On larger presses, the total slide weight must then be distributed among the quantity of safety blocks required.
The ram is usually adjustable; therefore, wedges or the adjustable screw device is offered to provide a proper fit. If the die takes up most of the space on the die set, it may be difficult to find a place to insert the block. To avoid accidentally stroking the press or leaving the safety block in the die after use, an electrical power cut-off interlock system should be used.
Note: Electrical interlocking of die safety blocks to the machine's motor and control circuits is required by ANSI B11.19.
ALUMINUM DIE SAFETY BLOCK SYSTEM
This high-strength die safety block is lightweight and comes in several sizes. The unique shape and mechanical properties of the 6061- T6 material have been calculated according to stringent structural alu­minum design analysis standards to provide high strength.
To determine the number of die safety blocks required, the static load each die safety block will support, and the length of each block, please follow the instructions below and on the next page.

1. Determining the static load the die safety block(s) will support:

The actual static load that the die safety block(s) will support is determined by adding the actual weights of the press slide and slide components (ram-adjustment assembly, connection rod lsI or pitman armIs], and the upper die).
If this weight cannot be determined, an approximate static load can be calculated using the information and formulas on the next page.

Allow 2000 pounds of static load for each cubic foot displaced in the press bed area (front to back x right to left) multiplied by the shut height (die space) of the press. Note: When using this formula, the calculated approximated static load has a safety factor of two (2).
Formulas:
Press Bed Area (sq in) x Shut Height (in)    = Cubic Feet Displaced Cubic Inches/Cubic Feet (Constant)
(1728 cu in/cu ft)
Cubic feet displaced x 2000 Ib/cubic foot = Total Static Load
Example:
(Press Bed Area) (Shut Height)
48 in by 96 in x 24 in   =  110,592 = 64 cu ft
1728 cu in/cu ft          1728
64 cubic feet displaced x 2000 Ib/cu ft = 128,000 lb static load

1. Determining the Die Safety Block Length

With the machine at the top of its stroke; stroke up-adjustment up (S.U.AU.-see previous page), mea­sure the space between the upper and lower die set plates (not the distance between the bolster and slide). This gives the maximum safety block length. To determine the stroke up-adjustment down (S.U.AD.-see previous page) measurement, subtract the ram adjustment from the S.U.AU. figure. This prOvides the minimum length of the die safety block.
            Total Length of Die Safety Block Required__________"

EXCEPTIONS

1. If wedges will be used, subtract 1-1/2" maximum. This is an allowance for variation in the stopping point of the crankshaft or adjustment of the ram.

            Total Length of Die Safety Block Required__________"

1. When an adjustable screw is added to an octagonal safety block, the minimum length of the aluminum portion of the safety block is as follows:
   For small and medium safety blocks
   2-1/2” plus the size of the adjustable screw device
   For large safety blocks
   3" plus the size of the adjustable screw device
   When an adjustable screw device is added to an octagonal safety block and the screw is all the way inside of the safety block, it will add 2" to the overall length of small and medium safety blocks and 2'12" to the overall length of large safety blocks. Therefore, subtract 2" for small or medium blocks and 212" for large blocks to determine the length of the aluminum portion of the die block.
   Example: If the minimum overall length of the small or medium safety block reqUired is 1012" with any size adjustable screw device, the aluminum portion of the safety block would be 812" (1012" - 2" = 812").
   Example: If the minimum overall length of the large safety block required is 16" with any size adjustable screw device, the aluminum portion of the safety block would be 1312" (16" - 212" = 13W').
               Total Length of the Aluminum Portion of the Die Safety Block_________"

1. Determining the Size of the Die Safety Block

The size of the die safety block (small, medium, large) is determined by one or both of the following factors:

1. The size of the block itself and the area available in the die. (See static load charts.)
2. The static load capacity of the block (small, medium, large) versus the total static load being supported. (See static load charts.)

To determine the number of safety blocks required, the static load each safety block will support, and the length of each block, please see tables above. The X-shaped safety blocks can be furnished four different ways:

1. Cut to length with a hole and pin for an interlock chain or wedges
2. Cut to length only
3. In a nine-foot length
4. Cut to length with a hole and pin for an interlock chain or wedges and a base plate installed (order base plate separately)

Weight of Blocks

Small

0.681 lb/in

Large

1.250 lb/in

Small

Large

A

4"

5-3/4"

B

1 "

1-1/4"

Small

Large

Way Furnished* (* Powder coating available on request)

Part No.

Part No.

A

KTS-609

KTS-610

B

KTS-605

KTS-606

C

KTS-607

KTS-608

D

KTS-635

KTS-636

Maximum Approximate Static Load Per Block in Pounds Tons * (*The approximate static loads shown in this chart have a built-in safety factor of two.)

Block Length

Small

Large

1"-24"

97,000 (48)

203,000 (101)

24-1/2"-30"

90,000 (45)

189,000 (94)

30-1/2"-36"

86,000 (43)

171,000 (85)

36-1/2"-42"

84,000 (42)

169,000 (84)

42-1/2"-48"

73,000 (36)

165,000 (82)

48-1/2"-54"

71,000 (35)

146,000 (73)

54-1/2"-60"

69,000 (34)

144,000 (72)

The U-shaped safety blocks can be furnished three different ways:

1. Cut to length with a hole and pin for an interlock chain or wedges
2. Cut to length only
3. In a nine-foot length

Weight of Blocks

Small

0.638 lb/in

Medium

0.879 lb/in

Large

1.17 lb/in

Small

Medium

Large

A

4-5/8"

5-1/2"

6-3/4"

B

4"

4-7/8"

5-1/2"

C

2-5/8"

3-1/4"

4-1/4"

Small

Medium

Large

Way Furnished* (*Powder coating available on request)

Part No.

Part No.

Part No.

A

KTS-561

KTS-562

KTS-563

B

KTS-564

KTS-565

KTS-566

C

KTS-554

KTS-555

KTS-556

Maximum Approximate Static Load Per Block in Pounds Tons * (*The approximate static loads shown in this chart have a built-in safety factor of two.)

Block Length

Small

Medium

Large

1"-24"

88,500 (44)

126,000 (63)

169,500 (84)

24-1/2"-30"

87,000 (43)

123,000 (61)

166,000 (83)

30-1/2"-36"

84,000 (42)

120,500 (60)

162,000 (81)

36-1/2"-42"

81,500 (40)

117,500 (58)

159,000 (79)

42-1/2"-48"

79,000 (39)

114,000 (57)

156,000 (78)

48-1/2"-54"

76,500 (38)

112,000 (56)

152,000 (76)

54-1/2"-60"

74,000 (37)

108,500 (54)

148,500 (74)

The octagonal safety blocks can be furnished four different ways:

1. Cut to length with a hole and pin for an interlock chain and with an adjustable screw device and/or base plate installed (order adjustable screw device and/or base plate separately; see below)
2. Cut to length with a hole and pin for an interlock chain or wedges
3. Cut to length only
4. In a nine-foot length

Weight of Blocks

Small

0.833 lb/in

Medium

1.12 lb/in

Large

1.58 lb/in

Block Size

Small

Medium

Large

A

4-5/8"

5-1/2"

6-3/4"

B

3-1/2"

4-1/4"

5-1/4"

Small

Medium

Large

Way Furnished * (*Powder coating available on request)

Part No.

Part No.

Part No.

A

KTS-589

KTS-590

KTS-591

B

KTS-592

KTS-593

KTS-594

C

KTS-595

KTS-596

KTS-597

D

KTS-599

KTS-600

KTS-601

Maximum Approximate Static Load Per Block in Pounds (Tons)* (*The approximate static loads shown in this chart have a built-in safety factor of two.)

Block Length

Small

Medium

Large

1"-24"

190,000 (95)

275,500 (137)

289,500 (144)

24-1/2"-30"

173,000 (86)

258,000 (129)

258,000 (129)

30-1/2"-36"

169,500 (84)

244,000 (122)

245,000 (122)

36-1/2"-42"

164,500 (82)

232,000 (116)

234,500 (117)

42-1/2"-48"

158,000 (79)

226,500 (113)

223,500 (111)

48-1/2"-54"

155,500 (77)

226,000 (113)

211,000 (105)

54-1/2"-60"

155,000 (77)

218,500 (109)

210,500 (105)

This heavy-duty steel screw device is added to the octagonal shaped safety blocks. These screws are needed to prevent any space between the block and die when various dies are used or when the slide is adjusted.
Note: if an adjustable screw device is mounted to an octagonal safety block, you must use the approximate static loads shown in the chart. This is because the adjustable screw devices will not hold as heavy a static load as the octagonal safety blocks by themselves.

Adjustable Screw Device

Octagonal Safety Block Size

Inches of Adjustment

Part No.

Maximum Approximate Static Load Per Adjustable Screw Device in Pounds (Tons)*

Small

2"

KTS-574

106,000 (53)

4"

KTS-584

102,500 (51)

6"

KTS-625

98,500 (49)

8"

KTS-626

94,500 (47)

10"

KTS-627

91,000 (45)

12"

KTS-622

87,500 (43)

Medium

2"

KTS-575

73,000 (36)

4"

KTS-585

70,000 (35)

6"

KTS-628

67,000 (33)

8"

KTS-629

64,000 (32)

10"

KTS-630

61,000 (30)

12"

KTS-623

58,000 (29)

Large

6"

KTS-598

189,000 (94)

8"

KTS-631

181,000 (90)

10"

KTS-632

174,000 (87)

12"

KTS-624

167,000 (83)

This safety block base can be added to U-shaped, octago­nal-shaped, and X-shaped safety blocks. The base adds stability to help prevent the die block from tipping over.
Available in 1/2" thick steel or aluminum.

Steel Bases for U-Shaped and OctagonaI-Shaped Safety Blocks

Part No.

Description

Dimensions

STL-053

Mini base

6" x 6"

STL-049

Small base

8-5/8" x 8-5/8"

STL-050

Medium base

9-1/2" x 9-1/2"

STL-051

Large base

10-3/4" x 10-3/4"

Steel Bases for X-Shaped Safety Blocks

Part No.

Description

Dimensions

STL-057

Small X-base

4" x 4"

STL-058

Large X-base

6" x 6"

Aluminum Bases for Octagonal-Shaped Safety Blocks

Part No.

Description

Dimensions

KTS-638

Small base

6" x 6"

KTS-640

Medium base

8" x 8"

KTS-641

Large base

10" x 10"

Aluminum Bases for X-Shaped Safety Blocks

Part No.

Description

Dimensions

KTS-637

Small X-base

4" x 4"

KTS-639

Large X-base

6" x 6"

These wedges prevent hazardous movement of the press slide if a space is created between the block and die when various dies are used or when the slide is adjusted. All cut-to-length wedges are furnished with a 24" chain. Available in aluminum or hardwood.

Safety Wedges for Safety Blocks

Part No.

Description

KTS-S71

6" aluminum wedge for small blocks

KTS-S72

7" aluminum wedge for medium blocks

KTS-S73

8" aluminum wedge for large blocks

KTS-S70

Aluminum wedge material in a 9' length

KTS-642

Hardwood wedge for all block sizes

These holders are designed to accept U-shaped, octagonal, X-shaped, and adjustable safety blocks. They are constructed of heavy-gauge steel and painted safety orange. The holders attach easily to the machine with two 1/4" fasteners. A strap is furnished with each holder to keep the block in place. Safety wedges can also be stored in the holders.

Holders

Part No.

Dimensions

KTS-003

8" x 8" X 14"

KTS-OOS

10-1/2" x 10-1/2" x 14"

KTS-019

10-1/2" x 10-1/2" x 24"

KTS-020

12" x 12" x 30"

LIFTING HANDLE-PART NO. KTS-633
The aluminum lifting handle is a con­venient option for all safety blocks that are used frequently.

According to ANSI B11.19-2003, safety blocks "shall be interlocked with the machine to prevent actuation of hazardous motion of the machine." The following interlock systems will satisfy this requirement. The interlock must be interfaced into the control system so that when the plug is pulled, the power to the main drive motor and control is disconnected. If the machine has a mechanical energy source, such as a flywheel, it must come to rest before the die block can be inserted. The interlock system is available in a yellow plug with one con- tact or an orange plug with two contacts. The interlock system includes the plug, a 12" or 24" long chain, a receptacle, and an electrical mounting box.
Part No. KTS-S03: One-contact interlock system with 12" chain
Part No. KTS-S18: One-contact interlock system with 24" chain
Part No. KTS-S34: Two-contact interlock system with 12" chain
Part No. KTS-S33: Two-contact interlock system with 24" chain

WARNING LABELS
PART NO. KST-323-English
PART NO. KST-323S-Spanish
The warning label illustrated to the right is provided with all safety blocks and should be affixed directly to each safety block. If a safety block is not tall enough for the label to fit, affix it to a prominent location on the machine. All personnel operating or working around the machine must be required to read, understand, and adhere to all warnings on this label. If the label becomes destroyed or unreadable, it MUST be replaced. Contact the factory immediately for a replacement label and do not operate the equipment until the warning label is in place.

MAXIMUM LOAD LABEL-PART NO. KST-330
The maximum load label shown to the right is provided with all safety blocks and is affixed directly to each safety block. If the label becomes destroyed or unreadable, contact the factory for a replacement label. The maximum load in tons should be written legibly on the label in permanent marker based on the maximum load chart.

These adjustable safety blocks feature a tough malleable-iron bell-bottom base, a convenient handle for lifting, and precision-cut acme threads for easy adjustment and extra rigidity. The adjusting screw can be easily adjusted up or down by hand. Turning holes are also provided in the screw neck to facilitate the use of a turning bar, if required.

Part No.

Capacity in Tons

Length
Closed

Screw
Adjustment

Length Screw
Adjustment Up

BaseDiameter

Weight in Pounds

Safety Block Holder Part No.

KTS-S20*

10

6-3/4"

1-1/4"

8"

4-7/8"

8

KTS-003

KTS-S21

10

8-3/4"

3-1/2"

12-1/4"

5-5/8"

10

KTS-003

KTS-S22

10

12-3/4"

7-1/4"

20"

6-1/2"

13

KTS-003

KTS-S23

20

9-1/2"

2-3/4"

12-1/4"

6-3/8"

18

KTS-003

KTS-S24

20

11-1/2"

4-1/2"

16"

6-5/8"

22

KTS-003

KTS-S2S

20

17-1/2"

9-1/2"

27"

7-3/4"

35

KTS-005

KTS-S26

24

11-3/4"

3-1/4"

15"

7-1/4"

31

KTS-005

KTS-S27

24

15-3/4"

6-1/2"

22-1/4"

7-7/8"

40

KTS-005

KTS-S28

24

21-3/4"

12"

33-1/4"

9-1/4"

56

KTS-005

*Does not have a handle.