A machine that can snap a thick steel bar in a fraction of a second can take a finger just as easily. Safety around a stationary electric shear requires militant discipline. There are two primary hazard zones on these machines: the cutting block and the drivetrain.
The most obvious danger is the pinch point at the blades. Modern commercial cutters feature heavy steel safety guards over the cutting mechanism, allowing only enough space to slide the bar in. Never remove these guards. I train my guys to use the foot pedal operation whenever possible; this keeps both hands on the long end of the rebar and entirely away from the machine chassis during the shear cycle.
The second hazard is the belt drive system. The belts and heavy pulleys spinning at high RPMs represent a severe entanglement hazard. Loose clothing, a lanyard, or even a glove can get caught, pulling the operator into the machine instantly. Ensure the factory sheet-metal guards over the motor and belts are securely bolted down before the machine is ever plugged in. Furthermore, implement a strict Lock-Out/Tag-Out (LOTO) procedure; if an operator is changing blades or clearing a jam, the machine must be physically unplugged from the power source, not just switched off.
