Define the emergency response
Specify what hazardous functions must stop and how the machine should respond when the function is actuated.
EMERGENCY STOP
AS/NZS 4024.1604 emergency stop design guide
A plain-English guide to where emergency stop fits in a machinery safety strategy—and where it does not.
FROM STANDARD TO SCOPE
Four conversations to have before the layout is locked
Use AS/NZS 4024.1604 to make emergency-stop provision clear, reachable and aligned with the machine risk strategy. The exact decisions still depend on the machine, tasks, risk assessment and current authorised standard.
Place devices around real work
Consider operator positions, access points and foreseeable emergency intervention—not just the control cabinet.
Make operation obvious
Device form, colour, location and labelling should support fast recognition and deliberate action.
Control reset and restart
Reset should not itself create a hazardous restart; the wider control logic and operating process matter.
WHY IT MATTERS
Emergency stop is the last line of intervention—not the first line of defence
Its job is to help avert or reduce harm when an emergency develops. It does not replace risk reduction, fixed or interlocked guarding, safe access or isolation.
THE COMPLETE DESIGN PICTURE
One standard rarely works alone
Risk assessment, physical guards, safety distances, interlocking, unexpected start-up and emergency-stop functions are connected. Follow the regional hub to move between the relevant guides without losing the project context.
Edition and jurisdiction note
Standards Australia identifies AS/NZS 4024.1604:2019 as setting requirements and design principles for the emergency-stop function. Confirm current status before use. Standards and guidance support—not replace—a project-specific risk assessment, applicable WHS/HSWA duties, regulator guidance and competent professional advice.
COMMON QUESTIONS
AS/NZS 4024.1604 FAQs
Does every machine require the same number of emergency-stop devices?
No. Quantity and location depend on the machine, operating positions, access, hazards and risk assessment.
Can emergency stop replace an interlocked guard?
No. Emergency stop is a complementary protective measure and should not be used as a substitute for appropriate safeguarding.
Can reset automatically restart the machine?
Reset and restart behaviour must be deliberately designed so reset does not itself create a hazardous condition.
Turn the standard conversation into a buildable guard layout.
Send the machine layout, photos and access requirements. We’ll help shape a practical modular guarding concept for your project team to assess.
Start the guarding conversationCommercial information only. This page is not legal, engineering or certification advice and does not reproduce the controlled requirements of the standard.
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