Start with actual use
The survey records normal operation, setting, cleaning, fault recovery and maintenance instead of treating the machine as a static shape.
Existing machinery & PUWER
PUWER Machine Guarding Upgrades
Survey-led retrofit guarding for older, modified or incompletely guarded machinery—developed around accessible hazards, real work tasks and the agreed improvement scope.
- Design
- Machine-specific
- Delivery
- Survey to handover
- Coverage
- Great Britain
Illustrative metalworking scene.
BMG / SOLDirect answer
When does existing machinery need a guarding review?
A guarding review is valuable when dangerous parts are accessible, guards are missing or frequently removed, machinery has been modified, access tasks have changed, or the current arrangement makes cleaning and maintenance impractical. PUWER applies to work equipment regardless of age or origin.
The final safeguard must follow the machine-specific risk assessment, intended use and agreed modification scope.
Project outcomes
Guarding that supports safe access and productive use.
Physical construction, access and safety interfaces are developed together so the guard does not create avoidable operating or maintenance problems.
Prioritise accessible hazards
Dangerous movement, ejection, trapping, reach paths and unexpected restart are considered when the physical guard and access strategy are defined.
Deliver a practical upgrade
The agreed scope can continue through detailed design, fabrication, installation, interface work and project handover.
Design brief
Five decisions to resolve before fabrication.
These questions turn a broad guarding request into a machine-specific scope that can be reviewed, manufactured and installed.
- 01Record the machine, existing safeguards and foreseeable intervention tasks
- 02Identify accessible dangerous parts and relevant PUWER actions
- 03Separate fixed guarding needs from routine movable access
- 04Resolve interlocking, guard locking and control-system interfaces
- 05Agree drawings, checks, residual responsibilities and handover evidence
Typical applications
Built around the equipment and task.
Frequently asked
PUWER Machine Guarding Upgrades questions.
Concise project guidance for specifiers, engineers and dutyholders. The actual machine review determines the final approach.
Ask the engineering teamDoes PUWER apply to old machinery?+
Yes. HSE guidance explains that PUWER is intended to ensure work equipment is safe to use regardless of its age, condition or origin. The dutyholder remains responsible for managing the risks from the equipment.
Is fitting a new guard enough for PUWER?+
Not always. The review should consider the hazard, foreseeable access, isolation, controls, maintenance, inspection and whether the guard can be bypassed or creates another risk. The final scope depends on the machine.
Can you replace missing or damaged machine guards?+
Yes. Replacement guarding can be reverse-engineered around the machine, but the opportunity should also be used to confirm access, strength, fasteners, openings and safety-device interfaces are suitable for current use.
Do you provide a statutory PUWER inspection?+
This service page describes a machine-guarding survey and upgrade pathway, not a blanket certification of the complete workplace or every PUWER duty. The exact assessment, design and verification responsibilities are agreed for each project.
Start with the machine and the task
Need puwer machine guarding upgrades designed around your site?
Send photographs, dimensions or a short description. We will help define the survey, design and installation scope.