Safety Guarding 101

Common Guarding Violations—and How to Fix Them Before an Inspection

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Belt Conveyor Guarding

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January 14, 2026

Inspections rarely fail operations because of obscure rules or unexpected requirements. In most cases, citations stem from well-known guarding issues that have been overlooked, deferred, or “temporarily” fixed for far too long.

The good news?
Many of the most common compliance violations are preventable—if you know what inspectors look for and address issues proactively.

Below, we break down the most frequent safety guarding violations seen in mining and heavy industrial environments, and how to fix them before an inspection turns into downtime, fines, or worse.

Why Guarding Violations Are So Common

In mining environments, guarding often competes with:

  • Production pressures
  • Aging equipment
  • Limited maintenance windows
  • Temporary fixes becoming permanent solutions

Inspectors understand operational realities, but they also focus heavily on exposure risk. If a moving part is accessible and unguarded (or poorly guarded), it’s a citation waiting to happen.

1. Unguarded Moving Parts on Conveyors

The Violation

Exposed:

  • Nip points
  • Tail pulleys
  • Head pulleys
  • Return rollers

These are among the most frequently cited compliance issues, especially on belt conveyors.

Why It Happens

  • Guards removed for maintenance and never reinstalled
  • Incomplete coverage on older conveyor systems
  • Custom equipment with no original guarding

How to Fix It

  • Install fixed, compliant conveyor guards that fully enclose pinch points
  • Use maintenance-friendly designs that can be removed and reinstalled quickly
  • Ensure guards are durable enough to stay in place—not bypassed

👉 A guard that slows maintenance will eventually be removed. A guard designed for access stays installed.

2. Improvised or “Temporary” Guarding

The Violation

Use of:

  • Plywood
  • Expanded metal zip-tied in place
  • Bent sheet metal
  • Makeshift covers

Improvised guarding does not meet recognized safety compliance standards.

Why It Happens

  • Quick fixes after inspections
  • Budget delays
  • “We’ll replace it later” mentality

How to Fix It

  • Replace temporary solutions with well-designed, purpose-built guards
  • Ensure guards are:
    • Securely fastened
    • Designed for the specific equipment
    • Able to withstand the environment (dust, vibration, impact)

👉 Temporary fixes often cost more long-term, through repeat citations and rework.

3. Guards Removed for Maintenance and Not Reinstalled

The Violation

Guards missing entirely—or reinstalled incorrectly—after maintenance work.

Why It Happens

  • Guards are heavy, awkward, or time-consuming to remove
  • No clear ownership for reinstallation
  • Maintenance crews under time pressure

How to Fix It

  • Use ergonomic, single-person removable guards
  • Standardize guard reinstallation as part of maintenance procedures
  • Eliminate “all-or-nothing” guards that discourage proper use

👉 If guards are easy to remove, they’re more likely to be put back.

4. Inadequate Coverage of Rotating Equipment

The Violation

Exposed:

  • Couplings
  • Shafts
  • Chains
  • Belts

Partial guarding that still allows reach-through or accidental contact is a common compliance finding.

Why It Happens

  • Guards designed for one configuration but applied elsewhere
  • Equipment modifications over time
  • Generic guards that don’t fit properly

How to Fix It

  • Use custom-fit guarding that fully encloses rotating components
  • Ensure no reach-through gaps exist during normal operation
  • Reassess guarding when equipment is modified or relocated

5. Guards That Create New Hazards

The Violation

Guards that:

  • Require awkward lifting
  • Create pinch points during removal
  • Obstruct visibility or access
  • Encourage bypassing

Safety authorities evaluate whether guarding introduces secondary risks

Why It Happens

  • Heavy steel guards
  • Poor ergonomic design
  • No consideration for maintenance workflow

How to Fix It

  • Choose ergonomic guarding designed for real maintenance conditions
  • Use lightweight but durable materials
  • Design guards to support safe access—not block it

👉 Good guarding protects workers and supports the job they have to do.

How to Prepare for a Workplace Safety Inspection

A proactive approach makes inspections far less disruptive:

Walk Your Conveyors and Equipment

  • Look for exposed moving parts
  • Check for missing or damaged guards
  • Identify temporary fixes

Talk to Maintenance Teams

  • Ask which guards are avoided or removed
  • Identify access pain points

Standardize Guarding Solutions

  • Replace one-off fixes with consistent, compliant designs
  • Reduce variability across the site

Address High-Risk Areas First

  • Conveyors
  • Rotating equipment
  • High-traffic maintenance zones

Proactive Guarding Is Cheaper Than Reactive Compliance

Safety inspections don’t just test compliance—they expose operational weaknesses. Poor guarding often leads to:

  • Repeat citations
  • Extended downtime
  • Increased injury risk
  • Higher long-term costs

Modern guarding solutions are no longer just about compliance. When designed correctly, they:

  • Reduce maintenance time
  • Stay installed
  • Improve safety culture
  • Protect uptime

Final Thought

Guarding violations are rarely a surprise—they’re usually the result of known issues left unresolved.

Fixing them before an inspection isn’t just about avoiding citations. It’s about building a safer, more efficient operation that doesn’t rely on shortcuts.

If your team is preparing for an inspection—or wants to reduce risk proactively—now is the time to address guarding the right way.

Join Our Free Guarding & Safety Webinar

If safety compliance, conveyor safety, and rotating equipment hazards are top of mind for your operation, this upcoming webinar will give you practical, real-world guidance you can apply immediately.

Making Mining Safer: Safety Guarding Essentials for Conveyors & Rotating Equipment

From Compliance to Confidence: Guarding for Safer Mining Sites

In this session, we’ll cover:

  • Common guarding issues inspectors flag most often
  • Real-world guarding examples from active mining sites
  • How properly designed guarding improves safety and maintenance efficiency
  • Practical steps to reduce risk before your next inspection

📅 Date: January 22, 2026
🕚 Time: 11:00–12:00 ET
🎓 Format: Live webinar with real-world examples

👉 Enroll Now to reserve your spot and learn how proactive guarding can help you move from reactive compliance to confident operations.

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