Top 5 Machine Guarding Mistakes And How to Avoid Them

Are Your Machine Guards Really Doing Their Job?

Let’s be honest, machine guarding isn't the most glamorous part of industrial safety. It’s one of those things that’s easy to overlook... until something goes wrong. And when it does? It’s rarely a small thing. We’re talking injuries, fines, halted production, sometimes all of the above.

The thing is, most people think their guarding is “good enough.” But “good enough” isn’t the same as compliant. Or effective. Or safe.

In this article, we’ll walk through the five most common machine guarding mistakes we see in UK manufacturing, warehousing, and logistics sites, and more importantly, how to avoid making them. We’ll talk practical fixes, relevant standards (yes, PUWER and UKCA/CE come up), and what to do when your setup just doesn’t cut it anymore.

Let’s get into it.

Mistake #1: Using Non-Compliant or Uncertified Guarding

This one happens a lot, and not always for the reasons you’d think.

Someone needs guarding fast. They go online, order a few panels, maybe even grab something secondhand. It’s metal, right? It bolts to the floor. It’ll do.

Except it won’t.

Here’s the risk: If your guards aren’t UKCA/CE, or don’t comply with BS EN ISO 14120 and 13857, you're exposing your team (and business) to a world of trouble. And no, just because a panel "blocks access" doesn’t mean it's safe under PUWER (Provision and Use of Work Equipment Regulations 1998).

We’ve been to sites where panels were tied together with zip-ties. Others where fixings weren’t even anchored into concrete. No certification. No documentation. Just crossed fingers.

The fix: Always go with a supplier who understands compliance. UKCA/CE modular systems should come with documentation proving they meet UK and EU safety standards, especially when machines fall under the Machinery Directive 2006/42/EC.

And if you're not sure? Ask. A supplier worth their salt won’t just sell you a panel. They’ll help you design a system that stands up to both impact and inspection.

Mistake #2: Poor Guard Placement or Access Design

Have you ever seen a guard installed exactly where someone needs to walk? Or worse, bolted across the only space a maintenance tech can reach a control panel?

Guards aren’t always removed because workers are lazy or reckless. Sometimes, the layout just doesn’t work. And when access becomes difficult, people do what they have to, cut through a panel, bypass a switch, or wedge the guard open with a stick. (Yes, that last one was real.)

Why this matters: Misplaced guards lead to tampering. Tampering leads to injury. And injury leads to... well, you know where this is going.

The better option: Start by thinking ergonomically. Can someone safely reach the machine for cleaning or maintenance without removing the guard? Are there interlocked access doors? Emergency stops nearby?

Modular systems with hinged panels, sliding doors, and safety interlocks make all the difference. Not just in safety, but in keeping your team from undoing your hard work.

And it doesn’t have to be expensive. We’ve reworked layouts just by swapping static panels for access doors and adjusting post locations. A few hundred pounds saved a multi-million-pound company from a repeat HSE audit. Sometimes it’s that simple.

Mistake #3: Inadequate Fixing or Structural Instability

This one’s sneaky. Your guarding looks solid, but is it?

We’ve been on sites where the panels were CE-marked and technically compliant, but they wobbled when leaned on. In one case, a pallet truck nudged a post and the entire corner fell like dominoes. No injuries, just a red-faced health and safety manager and a fast call to our team.

Here’s what gets missed: Machine guards aren’t just barriers. They’re supposed to withstand force. Whether it’s a robot arm swinging wide or a stray forklift brushing past, your system needs to stay standing.

How to avoid this one:

Always fix posts to a solid surface
Use vibration-resistant bolts in high-impact zones.
Check spacing between posts. Too wide, and the panels can flex.
Use anti-collapse mesh behind pallet racking if there's overhead risk.

Use colour coded systems where possible. Our standard colours for black panel and yellow posts are clearly visible to naked eyes making them create safe work environment.

It’s not just about box-checking compliance, it’s about making sure those guards stay where they’re supposed to.

Mistake #4: Not Designing for Maintenance or Upgrades

It’s tempting to install guarding like it’s a permanent fixture. Welded in place. No moving parts. Done and dusted, right?

Until three months later, when your team needs to upgrade a conveyor or add a new sensor, and suddenly you’ve got to cut your own guards to reach it. Now the CE marking is gone, the layout’s compromised, and the guard is basically scrap.

We’ve walked into plants where beautiful guarding had been butchered just to access a motor.

Here’s what to consider instead:

Is your layout modular? If something changes (and let’s be honest, it always does), can you remove and reconfigure panels without starting from scratch?
Can you include interlocked access or doors for routine jobs?
Is there a plan for future machines or layout changes?

Forward-thinking design doesn't mean over-engineering. It just means flexibility. That’s why Accessafe pushes modular mesh guarding. It’s strong, compliant, and reconfigurable without making your maintenance team curse your name.

Mistake #5: Failing to Train or Involve Staff

Last one, and maybe the most overlooked.

You can install the best guarding system in the world. But if your team doesn’t understand why it’s there, or how to work with it, they’ll find ways around it.

It’s not always sabotage. Sometimes it’s just someone rushing a job, or not realising a safety interlock is wired into the emergency stop. Other times it’s a new hire who never got proper onboarding.

So what’s the fix? Simple, but not easy.

Involve the people who actually use the equipment when planning guard layouts. They know the workflow better than anyone.
Include safety training as part of onboarding, and refresh it regularly.
Add visual signage (red = stop, green = access OK, etc.).
Make it easy to do the right thing. If someone has to climb over a guard because there’s no access panel nearby, the guard has failed its purpose.

We once had a client add feedback stations after each install phase. “Did this guarding help or hinder your job today?” The answers shaped future layouts and dropped incidents to zero.

Final Thoughts

Machine guarding isn’t a one-and-done task. It’s a living part of your safety culture. When it’s done right, it protects people, productivity, and your bottom line. When it’s done poorly, or ignored, it becomes the weakest point in your entire operation.

The mistakes we’ve talked about here? They’re common. We see them on brand-new installs and retrofits alike. But the good news is they’re fixable. Most of them, without huge cost or disruption.

If you’re unsure whether your current guarding is compliant, or if it’s just been a few years since anyone gave it a proper look, get in touch.

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