July 19, 2023 A Q&A on the Fan Block-R for Electrical Work Safety

Moving fan blades and components make HVAC maintenance and repair unsafe; Todd Truettner, ABM Safety Director, developed this safety item.

More than 100,000 workers in private industry suffered hand injuries in 2020 according to the U.S. Bureau of Labor Statistics. Moving fan blades and related components make HVAC maintenance and repair of particular concern, requiring organizations to look beyond the compliance checklist to prevent injury.

Todd Truettner, ABM Safety Director, took it upon himself to find a solution. With ABM’s support, Truettner developed the Fan Block-R. Here’s how his innovation is keeping workers safe.

What Is the Fan Block-R?

The Fan Block-R is an innovation I developed to improve electrical worker safety. In short, it is an angled sandbag that can be used in multiple ways to prevent unwanted movement in fans and fan elements. Its weight is calibrated to be placed on a fan’s blade to stop it from moving.

The angles of the Fan Block-R are designed specifically to go in between a shiv and a belt. Its sand filling makes it malleable enough to fit between the fan elements and it has a strap to lock it in place. It can also be strapped to the back of the fan unit to lock the pulley in place.

What Problem Does the Fan Block-R Address?

The Fan Block-R prevents fan blades and components from moving during service and maintenance. When servicing a fan, lockout/tagout procedures require workers de-energize the fan by disconnecting it from its power source. But cutting the electricity alone is not enough. The inertia generated by powering the fan down, as well as air flowing through the fan’s housing, can cause the blades to rotate, a process known as windmilling. Before the Fan Block-R, the standard practice for solving this issue was to place a 2×4 piece of wood in between the blades.

However, the 2×4 does not prevent the belt or pulley from moving, and it does not always hold against the movement of the blades. When the 2×4 method fails, it causes fractures, cuts, and even amputations. When I began to research ways to reduce windmilling, I realized there was nothing on the market more effective than the antiquated method.

How was the Fan Block-R Developed?

I knew there was a better way to prevent unwanted motion when servicing fans and I knew the tool needed to be durable, portable, and easy for engineers to incorporate into their existing practices. I was able to work with 70E Solutions, a family-owned safety equipment supplier, to create a custom solution.

What Makes the Fan Block-R A Necessity for Engineers?

Aside from the mechanics of the Fan Block-R, I considered factors that would increase the likelihood of engineers actually using it in the field, specifically:

• Multi-use: The Fan Block-R performs multiple functions, reducing the number of items engineers need to carry.
• Portable: Unlike a bulky piece of wood, the small size and strap make it easy for engineers to always keep with them.
• Durable: The Fan Block-R is made of ballistic nylon so it can’t easily be torn by sharp fan blades or general wear-and tear.

It’s great to hear feedback directly from the field: “It’s easy to use. It’s easy to carry. It’s easy to put in place.”

How Successful Has the Fan Block-R Been?

Since its creation, I’ve been fortunate to have the support of ABM leadership. At the local and regional level, senior managers and operations leaders are charged with ensuring Fan Block-Rs are included with all lockout/tagout kits and that ABM engineers are trained on how to use it. It’s amazing to see my “crazy idea” as a widely used injury prevention tool. There has not been a single injury related to fan blade or component motion at sites that use the Fan Block-R.

Attribute Responses to: Tod Truettner, Director, Engineering, at ABM Industries

Subscribe to Industry Today