OSHA-Compliant Machine Guards

Machine guards for industrial robots are physical protection systems that enclose machinery, robots or automated production cells, creating a continuous barrier between hazardous areas and operators.

The applicable construction standard is EN ISO 14120. ImpactGuard is Satech's solution for environments where guards must withstand high-energy impacts: tested to 2200 J (1623 ft-lb) with both 1.6 in (40 mm) and 2.4 in (60 mm) posts using a 0.8 in (20x20 mm) frame, and 2600 J (1917 ft-lb) with 2.4 in (60 mm) posts and a 1.2 in (30x30 mm) frame, per EN ISO 14120 Annex C.

ImpactGuard is built for high-impact environments: foundries and stamping lines, robotic welding or heavy assembly cells, islands with high-power industrial robots, and any setting where guards are exposed to repeated shocks or significant dynamic forces.

The structure with captive-screw posts maintains its structural integrity even under intensive operating conditions.

1.6 in (40 mm) posts support heights up to 103.1 in (2620 mm) with resistance up to 2200 J (1623 ft-lb): the standard choice for most high-impact applications.

2.4 in (60 mm) posts allow heights up to 125.2 in (3180 mm) with resistance up to 2200 J (0.8 in / 20x20 mm frame) or 2600 J (1917 ft-lb) (1.2 in / 30x30 mm frame), suited to critical installations or environments where projectile containment at height is also required.

For heights below 103.1 in (2620 mm) and non-extreme risk levels, the 1.6 in (40 mm) posts offer the most cost-effective solution without compromising safety.

A fixed guard must not be able to remain in place once its fasteners are removed. Screws, bolts and nuts must stay attached to either the guard or the machine to prevent them from falling into moving parts.

ImpactGuard's captive-screw system is designed to meet this requirement under EN ISO 14120 clause 5.3.9, keeping all fixing components secured to the structure even during maintenance disassembly.

In the United States, OSHA 29 CFR 1910.212(a)(2) separately requires that guards be affixed to the machine where possible, and secured elsewhere when attachment to the machine is not possible.

Perimeter guarding in robot cells refers to the physical barriers that isolate the robot's working area, preventing unauthorized access during automatic cycles.

In the United States, the reference standard for industrial robot systems is ANSI/A3 R15.06-2025, the U.S. national adoption of ISO 10218-1:2025 and ISO 10218-2:2025. It updates and replaces ANSI/RIA R15.06-2012, which is being withdrawn, and covers safety requirements for robot applications and robot cells, including safeguarding.

ImpactGuard is designed for high-impact environments, including robot cells. Selecting the right solution for a specific application still requires a Risk Assessment. See our reference standards page for more detail.

ImpactGuard is tested to 2200 J (1623 ft-lb) — 1.6 in (40 mm) and 2.4 in (60 mm) posts, both with a 0.8 in (20x20 mm) frame — and 2600 J (1917 ft-lb) with 2.4 in (60 mm) posts and a 1.2 in (30x30 mm) frame, per EN ISO 14120 Annex C.

Two impact forces are relevant to system selection: from outside (reference minimum 115 J / 85 ft-lb, equivalent to a person of roughly 200 lb / 90 kg falling against the guard) and from inside (material ejected by the process).

Determining the correct value for your specific application requires a Risk Assessment under EN ISO 12100, or the equivalent risk assessment process in ANSI B11.0.

Thanks to its framed mesh panel design, ImpactGuard can be installed at a minimum distance of 4.7 in (120 mm) from the hazard.

This distance is made possible by the 0.67 x 3.82 in (17 x 97 mm) mesh aperture, sized to prevent reaching through the panel to dangerous areas per EN ISO 13857, clause 4.2.4.1. In North America, the equivalent guard-opening and reach tables are those of ANSI B11.19.

However, mesh aperture alone is not sufficient to define correct guard positioning: the height of the hazard point must also be taken into account. A Risk Assessment is essential to determine both guard height and safety distance accurately.

Satech recommends periodic checks every three months, with particular attention for installations subject to frequent vibrations or impacts.

Checks include tightening the captive-screw fixings and inspecting mesh panels for any damage after impacts. Damaged components must be replaced immediately to maintain the rated 2200 J (1623 ft-lb) impact resistance.

For installations with integrated Safety Switches or interlocks, the maintenance program must include functional testing of the devices per EN ISO 14119 and the manufacturer's instructions.

A guard that has been damaged, loosened or left unsecured no longer provides the protection required by OSHA 29 CFR 1910.212, so keeping the perimeter in effective condition is part of maintaining compliance.

ImpactGuard can be installed on special floor types using a floor counter-plate, available in two versions: galvanized for gratings up to 1.2 in (30 mm) thick, and weld-on steel for metal surfaces where drilling is not possible or advisable.

Both versions are compatible with the 1.6 in (40 mm) and 2.4 in (60 mm) posts. Further details are available on our accessories and brackets page.