Updated July 2024
In this guide:
AS 4024:2019 Series - Safety of machinery
Ideagen Plant Assessor IP
People often ask where all the technical safety IP that Ideagen Plant Assessor holds comes from. The answer is quite simple; it comes from legislation, standards, Australian and international, from codes of practice and closely following developments in industry leading practice.
This often leads to discussion about standards and in particular the big kahuna of the machinery safety standards world, the 4024 series.
What are standards?
Standards are voluntary documents that provide guidelines, procedures and specifications for ensuring products, services and systems are safe, reliable and consistent. They cover a range of subjects such as environment, construction, energy and utilities and are regularly reviewed to stay up to date. Though on their own voluntary, standards are often referenced in legislation by our state and Commonwealth governments, effectively making them mandatory. Categories are:
- National standards: developed by a national accredited standards body such as Standards Australia
- International standards: developed by international bodies (ITU, ISO or IEC) for countries to adopt for national use
AS 4024-2019 Series – Safety of Machinery
The 4024:2019 Standards series focuses on the safety aspects of machinery use more than any other series and therefore the requirements for design. This series covers everything from the general principles of safety of machinery to risk assessment guidance and methods, controls, machine guarding and ergonomics, right through to anthropometric data (human body measurements).
These standards ensure machinery is designed with the utmost attention to safety, while allowing ease of use to users. By adhering to the 4024:2019 Standards, manufacturers and operators can ensure compliance, enhance workplace safety and align with industry best practices, which leads to improved efficiency and reduced risk of injury.
The AS 4024-2019 Series – Safety of machinery includes:
AS/NZS 4024.1100:2019 – Safety of machinery: Application guide
AS/NZS 4024.1201:2014 – Safety of machinery: General principles for design – Risk assessment and risk reduction
AS/NZS 4024:1204:2019 – Safety of machinery: Electrical equipment of machines General requirements
AS/NZS 4024.1302:2019 – Safety of machinery: Risk assessment – Reduction of risks to health from hazardous substances emitted by machinery – Principles and specifications for machinery manufacturers
AS/NZS 4024.1303:2014 – Safety of machinery – Risk assessment – Practical guidance and examples of methods
AS/NZS 4024.1401:2014 – Safety of machinery: Ergonomic principles – Design principles – Terminology and general principles
AS 4024.1501–2006 (R2014) – Safety of machinery: Design of safety related parts of control systems – General principles for design
AS 4024.1502–2006 (R2014) – Safety of machinery: Design of safety related parts of control systems – Validation
AS 4024.1503–2014 – Safety of machinery: Safety–related parts of control systems – General principles for design
AS/NZS 4024.1601:2014 – Safety of machinery: Design of controls, interlocks and guarding – Guards – General requirements for the design and construction of fixed and movable guards
AS/NZS 4024.1602:2014 – Safety of machinery: Interlocking devices associated with guards – Principles for design and selection
AS 4024.1603:2019 – Safety of machinery: Design of controls, interlocks and guards – Prevention of unexpected start–up
AS/NZS 4024.1604:2019 – Safety of machinery: Design of controls, interlocks and guarding – Emergency stop – Principles for design
AS/NZS 4024.1701:2019 – Safety of machinery: Human body measurements – Basic human body measurements for technological design
AS/NZS 4024.1702:2014 – Safety of machinery: Human body measurements – Principles for determining the dimensions required for openings for whole body access into machinery
AS/NZS 4024.1703:2014 – Safety of machinery: Human body measurements – Principles for determining the dimensions required for access openings
AS/NZS 4024.1704:2014 – Safety of machinery: Human body measurements – Anthropometric data
AS/NZS 4024.1801:2014 – Safety of machinery: Safety distances to prevent danger zones being reached by upper and lower limbs
AS/NZS 4024.1803:2019 – Safety of machinery: Safety distances and safety gaps – Minimum gaps to prevent crushing of parts of the human body
AS/NZS 4024.1901:2014 – Safety of machinery: Displays, controls, actuators and signals – Ergonomic requirements for the design of displays and control actuators – General principles for human interactions with displays and control actuators
AS/NZS 4024.1902:2014 – Safety of machinery: Displays, controls, actuators and signals – Ergonomic requirements for the design of displays and control actuators – Displays
AS/NZS 4024.1903:2014 – Safety of machinery: Displays, controls, actuators and signals – Ergonomic requirements for the design of displays and control actuators – Control actuators
AS/NZS 4024.1904:2014 – Safety of machinery: Displays, controls, actuators and signals – Indication, marking and actuation – Requirements for visual, auditory and tactile signal
AS/NZS 4024.1905:2014 – Safety of machinery: Displays, controls, actuators and signals – Indication, marking and actuation – Requirements for marking
AS/NZS 4024.1906:2014 – Safety of machinery: Displays, controls, actuators and signals – Indication, marking and actuation – Requirements for the location and operation of actuators
AS/NZS 4024.1907:2014 – Safety of machinery: Displays, controls, actuators and signals – System of auditory and visual danger and information signals
As you can see there are many parts to this standard. Many of the technical enquiries we receive stem from this standard.
Answering these enquiries is not as straightforward as we might like it to be. Recently we were asked where the Ideagen Plant Assessor requirements relating to two–handed controls came from. To provide a comprehensive answer to this question, we had to start with AS 4024.1201, and then follow 29 individual references to two–handed controls as well as four whole parts of the standard covering controls.
There have been additional parts added to AS 4024 covering specific types of machinery that were originally covered by their own standard. Conveyors are a good example. Conveyors were previously covered by AS 1755–2000, however they are now covered by AS/NZS 4024.3610, AS/NZS 4024.3612, AS/NZS 4024.3614 and AS/NZS 4024.3611.
Other machine specific parts of 4024 include:
- AS 4024.3001:2021 – Safety of machinery Machine tools safety – Presses – General safety requirements
- AS 4024.3002:2021 – Safety of machinery Machine tools safety – Presses – Safety requirement for mechanical presses
- AS 4024.3101:2008 (R2018) – Safety of machinery Materials cutting – Milling machines (including boring machines) – Safety requirements
Hopefully this has provided some insight into the technical research required to build and maintain the world’s largest and most advanced plant and equipment safety system, Ideagen Plant Assessor.
For more information on specific hazard guidance and more machinery safety information, check out more of our guides or our machinery obligations and legislation.
Disclaimer: This information is intended to provide general information on the subject matter. This is not intended as legal or expert advice for your specific situation. You should seek professional advice before acting or relying on the content of this information.
By Founder, Paul Dean
Originally published September 2022
Updated July 2024
About the Author
Paul Dean is the Founder of Ideagen Plant Assessor. Paul spent 10 years working in the construction industry, and 5 years in the machinery supply industry where he developed a deep knowledge about mobile plant and machinery compliance. Paul's idea for Plant Assessor was created in 2004 after working in the motor vehicle and machinery auction industry and realising the complexity and lack of standardisation when managing machinery and equipment compliance. Read More.
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