Machine Guarding (AS 4024)
Engineering-Led Inspections, Audits and Compliance Advice
Inadequate or poorly designed machine guarding remains one of the most common causes of serious workplace injuries in Australia. Rotating equipment, nip points, conveyors, drives and automated machinery all present risks that must be controlled through effective guarding.
The primary standard governing this in Australia is AS 4024 – Safety of Machinery.
Understanding and applying AS 4024 correctly — particularly to existing or modified machinery — requires engineering judgement, not just visual inspection.
What is AS 4024 – Safety of Machinery?
AS 4024 is a comprehensive suite of standards that covers:
Hazard identification and risk assessment
Guarding principles and design
Fixed and movable guards
Interlocks and control systems
Emergency stops
Safe access for operation, cleaning and maintenance
AS 4024 applies to:
New machinery
Existing plant
Modified or repurposed equipment
Imported machinery
Automated and semi-automated systems
It is closely linked to WHS legislation and is often referenced by regulators when assessing compliance.
Why Machine Guarding Compliance Matters
Poor machine guarding can result in:
Entanglement injuries
Crush and shear injuries
Amputations
Fatal incidents
From a compliance perspective, inadequate guarding can also lead to:
Regulatory notices or prosecution
Insurance issues
Shutdowns following incidents
Difficulty commissioning or modifying plant
A machine guarding audit to AS 4024 helps identify risks early and provides a clear path to compliance.
What Does a Machine Guarding Inspection Involve?
A proper machine guarding assessment goes well beyond “is there a guard fitted”.
At Trang Imagineering, machine guarding inspections typically include:
1. Hazard Identification
Identification of mechanical hazards (rotating parts, nip points, pinch points)
Assessment of access during operation, cleaning and maintenance
Review of foreseeable misuse
2. Guarding Assessment
Evaluation of fixed and movable guards
Guard strength, fixings and openings
Safe distances and reach requirements
Suitability of materials and construction
3. Control & Interlock Review
Assessment of interlocks and safety devices
Emergency stop accessibility and functionality
Interaction between guarding and control systems
4. Standards-Based Compliance Review
Assessment against relevant parts of AS 4024
Identification of non-conformances and partial compliance
Consideration of legacy equipment and practical upgrade pathways
5. Clear Engineering Reporting
Photographic evidence
Description of hazards and risks
Clear compliance findings
Engineering recommendations for remediation
Common Machine Guarding Issues We See
Some of the most frequent issues identified during audits include:
Guards removed or modified over time
Inadequate guarding of conveyors and drives
Unsafe access during cleaning or maintenance
Guards that meet dimensional rules but fail structurally
Poor integration between guarding and access systems (AS 1657 interface issues)
These are rarely obvious without a structured assessment.
Who Needs Machine Guarding Audits?
Machine guarding inspections are commonly required for:
Manufacturing facilities
Mining and processing plants
Agricultural and bulk handling equipment
Fixed and mobile plant
Commissioning of new machinery
Modification or relocation of existing plant
They are often initiated by:
Site owners and operators
Safety managers
Maintenance managers
Insurers
Regulators
Why Use an Engineer for Machine Guarding?
AS 4024 is a performance-based standard. Compliance is not always black and white.
Engineering involvement is critical when:
dealing with older or custom machinery,
assessing non-standard guarding solutions,
balancing safety, access and operational needs,
or certifying modifications.
Trang Imagineering provides engineering-led machine guarding inspections, ensuring:
technically defensible assessments,
practical and buildable solutions,
and documentation that stands up to regulatory scrutiny.
Machine Guarding Services with Trang Imagineering
Trang Imagineering specialises in mechanical and structural engineering compliance for industrial, mining and agricultural clients.
Our machine guarding services include:
AS 4024 machine guarding inspections and audits
Engineering advice on guarding upgrades and modifications
Integration with access systems (AS 1657)
Support for remediation design and certification
If you are unsure whether your machinery guarding complies with AS 4024, an engineering audit provides clarity and reduces risk.
Talk to Trang Imagineering
To discuss a machine guarding inspection or AS 4024 compliance audit, contact Trang Imagineering to arrange a site review or preliminary discussion.