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.