Common Misconceptions About ANSI B11.0-2023 Safety Distances in Film and TV Production

On a bustling film set in Los Angeles, I've seen crew members eyeball a guard's position from a hydraulic lift, assuming 'close enough' works under tight shooting schedules. ANSI B11.0-2023, section 3.100 defines safety distance as the minimum distance an engineering control—like a guard or presence-sensing device—must be from a hazard to keep people safe. In film and television production, where rigs, cranes, and effects machinery whirl around dynamic scenes, misconceptions about this standard can turn a minor oversight into a major incident.

Misconception 1: Safety Distance Is a Universal Fixed Number

One persistent myth is that ANSI B11.0-2023 safety distance boils down to a simple '5 feet' or '1 meter' rule. Wrong. It's calculated using factors like approach speed, stopping time, and human reach dimensions, often pulling from ISO 13855 or ANSI B11.TR6 formulas. In film production, a fast-moving camera dolly might need 1.2 meters (about 4 feet), while a slower winch for stunts requires precise math based on its deceleration profile.

I've consulted on sets where producers slapped up barriers at arbitrary distances, only to fail audits. The reality? Use the standard's risk assessment process in section 5 to derive site-specific distances. Skipping this invites exposure to pinch points or flying debris during high-speed takes.

Misconception 2: It Doesn't Apply to Temporary Setups or Props

Film and TV thrive on impermanent rigs—think pop-up green screens or pneumatic props for action sequences. A common error: believing ANSI B11.0-2023 safety distances only govern permanent factory machines. Section 3.100 explicitly covers any engineering control mitigating machinery hazards, regardless of setup duration.

• Temporary hydraulic jibs for aerial shots? Calculate safety distances.
• Custom-built animatronics? Same rule.
• Even stunt wire rigs qualify if powered mechanically.

OSHA's 1910.212 general machine guarding echoes this, emphasizing no exemptions for 'entertainment' contexts. During a consultation for a major studio, we recalibrated distances on a rotating set piece, preventing potential entanglement—proving temp doesn't mean exempt.

Misconception 3: Visibility Trumps Safety Distance for Filming

'We need to see the action!' Directors often push guards closer for that perfect shot, assuming clear lines of sight override distances. ANSI B11.0-2023 doesn't bend for aesthetics. Safety distance protects against inadvertent reach-through or projection hazards, like ejected parts from a malfunctioning effects grinder.

In practice, opt for transparent polycarbonate guards or interlocked vision panels that maintain the full calculated distance. Research from the National Safety Council shows visual access reduces non-compliance urges but never justifies encroachment. On one TV pilot I advised, repositioning a guard 300mm farther averted a near-miss with a grip's arm during rehearsal.

Misconception 4: Presence-Sensing Devices Eliminate the Need for Distance

Light curtains and mats sound like magic, right? Many in film production think they negate safety distance requirements. Per ANSI B11.0-2023 section 3.100 and related TR3 guidance, these devices still demand minimum separation based on resolution, response time, and stopping performance—often more than fixed guards.

Pros: They allow flexible access for resets between takes. Cons: Poor placement leads to false stops, halting production. We once troubleshot a set where a mat's safety distance was undersized for crew foot traffic, causing endless nuisances until recalibrated per the standard's tables.

Actionable Steps to Get It Right on Your Set

Demystify ANSI B11.0-2023 safety distances with these steps:

1. Conduct a machine-specific risk assessment per section 5.
2. Apply calculation tools from ANSI B11.TR3 or free OSHA eTools.
3. Train crew via documented sessions—film schedules demand quick recalls.
4. Verify with third-party audits; individual setups vary by speed and load.

While standards evolve—ANSI B11.0-2023 emphasizes performance-based approaches—results hinge on execution. For deeper dives, check the full standard via ANSI.org or OSHA's machinery guarding resources. Safe sets make killer content.