Machine Guarding with Wire Mesh: Australian Compliance Guide

Under Australian WHS legislation, a business has a duty to guard the dangerous parts of machinery it operates. That duty doesn't go away because a machine has been running safely for years, and it's often the first thing that comes up after a near-miss, an equipment upgrade, or a visit from SafeWork.

Wire mesh panels are one of the most widely used solutions for fixed and perimeter machine guarding in Australian manufacturing, food processing and logistics facilities, and for good reason: they're strong, they let operators see the machine cycle, and a modular system can go in without shutting the whole line down.

This guide covers what the standards expect, the main types of guarding, and how to plan a compliant wire mesh guarding system around your equipment.

What is machine guarding, and who needs it

Machine guarding is any physical barrier or device that prevents a person from reaching a hazardous part of a machine, whether that's a moving blade, a pinch point, rollers, or an area a robot arm sweeps through. If your business operates machinery with moving parts that could cause injury, from a single production line to a full manufacturing floor, you have an obligation to assess that risk and guard against it. This applies to manufacturers, food and beverage processors, timber and metal fabricators, and increasingly to warehouses running automated handling equipment.

The standard that matters: AS 4024.1

The AS 4024 series is the core Australian standard covering the safety of machinery, including how guards should be designed and positioned. In plain terms, it sets out a risk assessment process for identifying hazards, and it links the size of any gaps or openings in a guard to how far that guard sits from the danger point: the closer a guard is to the hazard, the smaller its openings need to be to stop someone reaching through. Because the exact figures depend on your specific machine and hazard, this is one area where it pays to work through the calculation with a qualified WHS advisor or engineer rather than estimating.

Types of machine guarding

• Fixed guarding: permanently fixed in place with no moving parts of its own, such as mesh panels bolted around a machine's danger zone. The most common and often the most cost-effective option.
• Interlocked guarding: tied to the machine's controls so the machine stops, or can't start, if the guard is opened.
• Adjustable guarding: fits around varying stock sizes or tooling, adjusted by the operator as needed.
• Self-adjusting guarding: moves automatically to let material through, then returns to the guarding position.

Most general perimeter and machine-surround applications call for fixed guarding, with interlocked gates added wherever operators need regular access.

Why wire mesh is a preferred material for fixed and perimeter guarding

• Visibility: operators and supervisors can see the machine cycle and spot problems without opening the guard.
• Airflow: an open mesh doesn't trap heat, dust or fumes the way a solid panel can.
• Rigidity: welded wire mesh resists impact and deformation far better than chain wire or light plastic mesh.
• Customisation: modular panels fit irregular machine footprints, unlike a one-size fabricated enclosure.
• Speed of install: a bolt-together mesh system goes up considerably faster than custom steel fabrication.

Key specifications to look for

• Aperture size: matched to the safety distance for your specific hazard, per AS 4024.2.
• Panel height: tall enough to prevent someone reaching over the top into the danger zone.
• Post and frame strength: rated for how the guard will actually be used, including any incidental contact from material handling equipment.
• Gate interlocking: fitted wherever operators or maintenance staff need frequent access to the guarded area.

Planning and installing a compliant machine guarding system

1. Risk assess the machine and identify every point where a person could contact a hazard.
2. Establish the required safety distance from the hazard to the guard, using AS 4024.2 as your reference.
3. Select a mesh aperture size and post spacing that meets that safety distance.
4. Plan the guard perimeter around the machine's actual footprint, including where access gates need to sit.
5. Install panels and posts, checking carefully for gaps at floor level and where panels meet.
6. Record the guarding as part of your WHS risk register and ongoing inspection schedule.

Because irregular machinery rarely fits a standard panel width, custom panels from 500mm to 1050mm let you build a fitted perimeter around almost any equipment layout, and a modular system can typically be installed in sections without shutting the whole facility down.

Get a quote for your machine guarding project. Bulk pricing is available for warehouse and manufacturing orders, and custom panel widths can be made to fit your equipment.

A simple compliance checklist

• Guard height prevents reaching over into the danger zone
• Aperture size checked against the required safety distance
• No reach-around gaps at floor level or panel joins
• Gates are interlocked or lockable where regular access is needed
• Guard is fixed securely to the floor or machine frame
• Guard doesn't obstruct emergency stops or clear sightlines
• Guarding is documented in your WHS risk register and inspection schedule

Frequently asked questions

Is wire mesh guarding compliant with AS 4024?

Welded wire mesh panels can meet AS 4024 requirements for many general fixed and perimeter guarding applications, provided the aperture size and mounting are matched to your specific risk assessment.

Can I install machine guarding myself?

Modular mesh systems are generally straightforward for your own team to install. That said, the underlying risk assessment and final sign-off should still involve a qualified WHS advisor.

What if my machinery has an irregular shape?

Custom width panels, from 500mm to 1050mm, can be combined with standard panels to build a fitted perimeter around almost any equipment footprint.

This guide is general information, not a substitute for a formal risk assessment or advice from a qualified WHS professional. Always confirm compliance against the current version of AS 4024 and the requirements of your relevant state or territory WHS regulator.