Treadmills are among the busiest pieces of equipment in most fitness facilities. They combine electrical components, moving belts, adjustable incline systems and members exercising at speed, often with limited supervision.
Despite this, treadmill safety and maintenance problems are often treated as servicing issues rather than day-to-day operational risks.
After more than 30 years working as a gym owner, manager, trainer, equipment specialist and safety consultant, FitSafe founder Selwyn Becker has seen how seemingly minor treadmill issues can contribute to injuries, equipment downtime and unnecessary repair costs.
The good news is that many problems provide warning signs before a serious failure occurs. Gym staff just need to know what to look for and what action to take.
Why treadmill safety and maintenance matter
AUSactive’s Work Health and Safety Guide recommends preventive maintenance programs for exercise equipment, supported by regular inspections and documented maintenance records. Its National Code of Practice also says equipment should be mechanically sound and installed, maintained and operated in accordance with the manufacturer’s written guidance.
This means treadmill safety involves more than booking a technician once or twice a year. Operators also need a practical system for:
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noticing visible changes in equipment condition
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checking that safety controls still work
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responding to reported faults
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removing unsafe machines from use
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maintaining adequate space around each treadmill
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keeping inspection and servicing records
The following five issues are a useful starting point.
1. Treadmills regularly left at a high incline
It’s common to find a treadmill left at a steep incline after a member finishes training.
An elevated deck isn’t automatically evidence that the treadmill is damaged. Some machines return to zero during a completed cool-down, while others remain at the last selected incline depending on their design and how the workout was stopped. Manufacturer instructions should always be checked for the specific model.
However, a treadmill repeatedly found at a high incline can still reveal an operational problem.
It may indicate that:
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members are stepping away before the workout has ended
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the incline control isn’t responding correctly
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the machine is being switched off before returning to its normal position
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staff aren’t resetting equipment between users
A steep starting position can also surprise the next member, particularly if they step onto the machine without noticing the deck angle.
What staff should do
Where the manufacturer permits it, return the treadmill to a neutral or level position after use. Confirm that the incline raises and lowers smoothly without unusual noise, hesitation or juddering.
A treadmill that won’t lower properly, moves unevenly or displays an incline error should be taken out of service and assessed by a qualified technician.
The aim isn’t simply to make the cardio area look orderly. It’s to leave the machine in a predictable condition for the next user and identify incline faults early.
2. Worn, slipping or misaligned walking belts
The walking belt is one of the treadmill components most directly exposed to wear.
A belt problem may appear gradually. Members may describe the treadmill as feeling uneven, jerky or slow before any obvious damage can be seen.
Warning signs include:
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the belt slipping or hesitating under load
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movement that surges rather than remaining consistent
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frayed or damaged belt edges
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the belt tracking to one side
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rubbing or chafing noises
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excessive heat or a burning smell
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visible damage to the belt or running deck
Precor’s maintenance guidance, for example, recommends daily inspection for slipping belts, loose components, unusual noises and worn electrical cords. It also advises removing a treadmill from use when servicing is required.
Belt alignment matters as well. A belt that continually moves off-centre may rub against the machine and become damaged. Manufacturer guidance warns that poor alignment can eventually cause tearing or fraying.
What staff should do
Staff can observe the belt and record problems, but belt tension and alignment adjustments should only be completed by someone who is trained and authorised to do so.
Working near a live belt and roller creates its own entanglement risk. The treadmill should be switched off and isolated before maintenance or adjustment work begins.
Where there is any doubt, prevent access to the machine and arrange professional inspection rather than continuing to operate it until the next scheduled service.
3. Emergency stop buttons and safety cords that don’t work
Most treadmills have at least two ways to stop the belt quickly:
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a prominent stop button
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a safety cord or lanyard connected to a magnetic key
Both features need to be present, accessible and functional.
A safety cord can become damaged, shortened, tied around the handrail or removed altogether. A stop button may look normal but fail to respond correctly when tested.
The Safe Work Australia plant code states that emergency stop controls should be prominent and immediately accessible. It also makes an important point: emergency stops are a back-up control, not a replacement for proper maintenance, safe equipment design and supervision.
Treadmill manufacturers likewise instruct users to attach the safety clip during use and describe how removing the magnetic key should bring the belt to a stop.
What staff should do
Emergency stop functions should be tested at a frequency consistent with the manufacturer’s instructions and the facility’s risk assessment.
The check should confirm that:
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the stop button responds correctly
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the safety cord and clip are present
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removing the magnetic key stops the belt
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the cord isn’t excessively worn or damaged
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the controls are clearly visible and accessible
A treadmill with a missing or failed emergency stop system shouldn’t remain available for member use.
4. Treadmills left running without a user
Members sometimes step off a treadmill without properly ending the workout. They may move to another machine, answer a phone call or assume the belt will stop automatically.
This leaves a moving surface waiting for the next person who approaches.
Some newer commercial treadmills include user-detection or automatic stop technology. However, this feature isn’t present on every machine and shouldn’t be assumed to be working without testing.
A member who steps onto a moving belt unexpectedly could lose balance before they have time to reach the controls.
What staff should do
Staff walking through the cardio area should look for treadmills operating without a user and stop them promptly.
Repeated occurrences may justify:
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clearer instructions near the console
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including treadmill shutdown in member inductions
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reviewing whether automatic stop settings are enabled
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positioning equipment so staff can see operating displays
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reinforcing the issue with members who repeatedly walk away
For 24-hour or unmanned facilities, the risk should also be considered as part of the facility’s monitoring and emergency arrangements.
5. Insufficient clearance behind the treadmill
Clearance behind treadmills is one of the most important, and most frequently compromised layout issues.
If a user falls or is carried off the back of the belt, they need an unobstructed area in which to land and move away from the machine. A wall, bench, bin, planter, storage unit or another piece of equipment can turn a fall into a much more serious impact or entrapment event.
Exact treadmill clearance requirements vary by manufacturer and model. As one example, Precor guidance specifies two metres of clear space behind certain treadmills, with additional clearance at the sides. Operators should confirm the requirements in the manual for every model in their facility rather than relying on one generic measurement.
AUSactive also expects exercise areas to provide adequate safe working space and not be arranged in a way that hinders safe equipment use.
Selwyn has personally witnessed a serious treadmill accident where insufficient space behind the machine contributed to the outcome. It’s a reminder that clearance isn’t spare floor space that can be gradually taken over by furniture or storage. It’s part of the treadmill’s safety zone.
What staff should do
Check the area behind every treadmill and make sure it remains:
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free from walls or fixed obstructions within the required clearance
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clear of loose equipment and storage
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free from bins, chairs and promotional displays
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unobstructed during both quiet and peak periods
Clearance should be reassessed whenever machines are moved, new equipment is installed or the gym layout changes.
When should a treadmill be removed from use?
A treadmill should be isolated when a fault could expose members or staff to harm.
Examples include:
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a belt that slips or suddenly changes speed
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an emergency stop that fails
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a missing magnetic safety key or cord
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damaged wiring or power components
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smoke, burning smells or unusual heat
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severe vibration or mechanical noise
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abnormal incline movement
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a machine that won’t stop normally
Switching off the machine isn’t always enough. It should be clearly marked as unavailable and prevented from being restarted accidentally. WorkSafe Victoria recommends safe isolation procedures during plant inspection, cleaning, adjustment and maintenance.
Only return the treadmill to service once the fault has been assessed, the required work has been completed and the machine has been confirmed as safe to use.
Why an independent equipment review can help
Gym teams become familiar with their surroundings. Over time, a small belt hesitation, missing safety cord or crowded treadmill layout can start to feel normal.
An independent gym safety review looks beyond whether each machine switches on. It considers:
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equipment condition
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placement and clearance
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emergency controls
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maintenance records
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fault reporting
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isolation procedures
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how staff and members use the equipment in practice
This can help operators distinguish between minor housekeeping issues, maintenance concerns and safety risks requiring urgent action.
Unsure whether the treadmills and other equipment in your facility are being checked thoroughly?
Book a FitSafe Free Safety Review to discuss your current equipment, maintenance and inspection systems. We’ll help you determine whether any immediate improvements or a more detailed gym safety audit are needed.
