A recent WorkSafe Victoria prosecution has highlighted how poorly designed or incomplete fencing around machinery can contribute to life-changing injuries – a key lesson for anyone involved in designing, supplying or installing fences and gates around plant and equipment.
In this case, a quarry was using a large rotary dryer, partially enclosed by a fence, to heat and dry limestone before crushing. The plant had several danger points where rotating rollers and cogs created a serious entanglement risk.
In November 2023, a worker was rostered to operate the dryer and asked to grease an unguarded drive gear cog. He entered the fenced-off area via an access gate and applied grease while the dryer was still running. During this process, his arm was pulled into the moving gear, resulting in injuries so severe that an amputation below the elbow was required.
WorkSafe’s investigation found that while there was a basic operating procedure, it did not include lock-out tag-out (LOTO) steps or clear direction on isolating the plant.
The company later admitted it would have been reasonably practicable to:
- Install secure fencing with no gaps fully enclosing the dryer
- Control access via a lockable gate
- Implement a documented LOTO procedure and provide workers with locks, tags and proper induction
WorkSafe has again stressed that guarding, compliant safety gates and correctly fenced-off danger zones are essential controls when working with machinery that has moving parts.
For fencing and gate contractors, this case underlines the importance of:
- Designing and installing machine-guarding fences that fully prevent access to danger points
- Ensuring gates to hazardous areas are lockable and controlled
- Coordinating fencing layouts with plant isolation, signage and safe access procedures
- Recognising that “partial” fencing or gaps in guarding can leave workers exposed to unacceptable risk
Robust fencing, guarding and gate design are not just perimeter solutions – they are critical safety controls wherever workers are exposed to plant and machinery.
