In industrial environments such as factories, warehouses, logistics facilities, abattoirs, and chemical plants, moving machinery is essential to day-to-day operations. But with that comes a clear responsibility: keeping people safe.
Machine guarding isn't just the best practice; it's often a legal requirement. Poor or missing guards remain one of the leading causes of serious injuries in the manufacturing sector. Proper machinery guarding doesn't just help you meet compliance; it protects your team, reduces risk, and keeps operations running smoothly.
That said, not all workplaces are the same. Different industries face varying risks, and the right solution in one setting may not be suitable for another.
In this guide, we break down how to choose the best panel for your machinery guarding, balancing protection, visibility, and performance for your specific needs.
What is a Machine Guard?
A machine guard, also referred to as industrial safety fencing, serves as an essential protective barrier intended to separate pedestrians from moving components, debris, and various risks associated with the use of manual or automated machinery.
Machines commonly used in Australian workplaces often have moving parts, sharp edges, and hazardous processes.
Common types of machinery in Australian industrial environments where worker safety would benefit from machinery guarding include:
- Power presses
- Conveyors
- Milling machines
- Metal cutting saws
- Lathes
- Drilling machines
- Woodworking equipment
- Meat grinders
By partitioning off hazardous areas and limiting reach through, reach under, and reach over, machine guards help prevent serious workplace incidents and safeguard workers while on the job.
Australian Standard 4024:2019
The Australian Standard 4024:2019 is a comprehensive set of standards that govern the safety of machinery in various settings throughout Australia.
This set of standards provides a comprehensive guide for designing, manufacturing, supplying, and using machinery safely.
Included in these standards is guidance on safety distances to prevent workers' upper and lower limbs from reaching danger zones, which relates to reaching in and through apertures.
There are several reasons for having an opening in a machine guard. The operator may need to insert or retrieve material, observe the work in progress, adjust the equipment, or clean the machinery.
The distance between a machine guard and the dangerous area must exceed the reasonable length of the following, plus a clearance allowance: including, but not limited to, fingers, hand, arm, and a portion of the shoulder (excluding the head and trunk).
Machine Guarding Best Practices
As workplace safety standards evolve, conducting a thorough risk assessment for every machine is more important than ever.
This process identifies hazards and helps determine the most effective machine safeguarding measures.
- Smart Machine Guarding Choices: Choosing the right machine guarding panels, such as welded mesh, sheet metal, or polycarbonate infills, ensures safety barriers are solid, securely mounted, and designed to prevent bypassing. Regular maintenance is essential to keep them effective and hazard-free (continue reading to learn more).
- The Role of Technology: Advanced solutions like safety sensors, light curtains, and interlocking devices are now key components of modern machine safety guards. These technologies enhance protection and help facilities meet strict safety regulations.
How to choose the right Industrial Safety Fencing Paneling
To select the appropriate infill panelling for machinery guarding, it is essential to understand the various types of panelling. The types of machinery guarding panels include:
- Welded Mesh - For areas where clear visibility is needed while maintaining safety.
- Sheet Metal - Often used in welding areas to prevent arc flash and grinding cells to contain airborne particles.
- Polycarbonate – Made from a transparent, highly durable material providing full visibility while offering additional protection from debris and contamination.
- Tube On Edge - Ideal for safety-critical environments that demand superior hygiene, visibility, and durability.
- Easy Fence - Designed for strong, flexible, and hygienic safety in industrial environments requiring frequent access and easy maintenance.
- Cantilever and Infill Panels - Built to provide effective coverage for small openings while maintaining structural integrity.
Machinery guarding panels come in standard configurations or they can be customised to suit specific applications.
Welded Mesh
Welded Mesh panels are constructed from steel wires welded together to form a rigid, grid-like panel.
Welded mesh panels provide strong physical protection while maintaining excellent visibility, making them ideal for environments where supervision and communication across the barrier are important.
Welded mesh is highly durable and resistant to impact, which makes it well-suited for:
- Factory & Manufacturing – where automated machines are in operation.
- Warehousing & Logistics – where partitioning and asset protection are essential.
Steel Mesh
Sheet Metal offers a sturdy, non-transparent safety barrier that is highly effective at containing hazards and blocking visual exposure.
These barriers are often used in welding and fabrication areas to prevent arc flash from reaching bystanders, and in grinding cells and machining zones to contain sparks, airborne particles, and debris.
The durability and heat resistance of sheet metal make it suitable in industrial settings such as:
- Automotive manufacturing where operating windows and shields are required,
- and any environment where both containment and protection from visual impairment hazards are required.
Polycarbonate
Polycarbonate panel infills are made from a transparent and durable material.
It offers impact resistance and optical clarity, allowing for full visibility while providing robust protection from flying debris, contamination, or accidental impacts.
Polycarbonate is frequently chosen for machine guards and safety screens in industrial and manufacturing settings, including:
- Healthcare and food processing - where hygiene and visibility are essential.
- Transportation - operator shields and high-impact windows.
Tube On Edge
Tube on Edge is a stainless steel machinery guard panel constructed with vertically oriented steel tubes, thereby creating a smooth, easy-to-clean surface with minimal ledges where dust, liquids, or contaminants can accumulate. Tube On Edge is especially suitable for environments with strict hygiene standards, such as:
- cleanrooms,
- food and beverage processing facilities,
- abattoir
- chemical and pharmaceutical,
- high-moisture zones,
- and sanitary production areas.
Easy Fence
Easy Fence is a modular, lightweight stainless steel fencing system designed for environments that require strong safety barriers while offering flexibility for frequent reconfiguration and easy maintenance.
Easy Fence is ideal for a range of general industrial settings, including but not limited to:
- warehousing,
- logistical facilities,
- and factory and manufacturing plants.
Cantilever and Infill Panels
Cantilever panels are horizontally mounted to close off open spaces without ground support, ideal for areas with uneven flooring or obstacles, and are adjustable for a precise fit.
Infill panels fill smaller gaps between posts or around obstructions, ensuring continuous protection and compliance with safety standards. Thanks to their frameless design, Infill Panels can be easily modified on-site to suit existing obstructions, such as pipework.
Cantilever and Infill Panels are widely used in industries including:
- Manufacturing & Warehousing: Defining access zones and protecting assets from operational hazards.
- Automotive & Robotics: Enclosing robotic cells or automated equipment, preventing unauthorised access or accidental contact.
- Logistics & Distribution: Creating secure walkways, partitioning vehicle and pedestrian traffic, and protecting inventory.
Case Study: Leading Transport Infrastructure Manufacturer
A well-known transport infrastructure engineering and manufacturing company located in Ballarat required customised fencing panels to delineate its Wheel shop's outer boundaries.
By implementing Machinery Guarding, the wheel shop could ensure clear separation between pedestrian paths and active work areas, minimising the likelihood of accidents caused by workers being in the same operating area as forklifts. This was customised to fit the unique site requirements.
Read the full case study to learn more: Leading Transport Infrastructure Manufacturer
Final Word: How to Choose the Right Panelling for Machinery Guarding
Selecting the right panelling for your machinery guarding will help create a safer, more compliant, and productive workplace.
Each panel type - welded mesh, sheet metal, polycarbonate, tube-on-edge, and easy fence - offers unique advantages, making them ideal for different environments and industrial operational requirements.
When deciding, always consider the hazards that are unique to your environment, the required level of visibility and supervision, any hygiene standards that need to be upheld, and the need for flexibility or future reconfiguration.
Conducting a comprehensive risk assessment and understanding the regulations of your industry will assist you in identifying the most suitable solution for your facility.
To learn more, download our comprehensive machine guarding checklist to help build an understanding of how to make your machine guarding compliant, safe, and accessible.
Remember: The right industrial safety fencing panel will protect your workers and help maintain smooth, safe operations as well as compliance with Australian safety standards.
Don't hesitate to consult with safety experts or machinery guarding specialists to ensure your investment delivers maximum protection and long-lasting value.
By making an informed choice, you're taking an essential step toward a safer and more productive workplace for everyone.
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