Abstract: Employee #1, the foreman of a gravel processing plant, noticed that some mud had built up on the face of the tail pulley on a conveyor. Knowing that such a build up will cause the conveyor belt to slide off to the side and become damaged from scraping against the metal frame, Employee #1 hastily tried to remove the caked mud. Compressed air did not work because he could not get close enough. He then inserted a metal bar through a slot in the screen guard and tried to scrape off the mud by sticking the bar across the rotating face of the pulley. However, a piece of bent, 1/4 in. rebar had wrapped itself on the pulley shaft, and struck the metal bar held by Employee #1. The metal bar slammed Employee #1's hands into the screen guard, pinning them there. An equipment operator saw the trouble, and freed Employee #1's hands by physically bending the metal bar. Another coworker shut down the plant's conveyor. Employee #1 was administered first aid at the scene and was then driven to the local hospital. He sustained serious hand injuries, and one finger had to be amputated.