Machinery Damage Exclusions: What's NOT Covered

When businesses invest in commercial insurance to protect their valuable machinery and equipment, they often assume comprehensive coverage. However, machinery breakdown insurance and commercial property policies contain numerous exclusions that can leave business owners exposed to significant financial losses. Understanding what's NOT covered is just as important as knowing what is protected.

This guide explores the common machinery damage exclusions found in commercial insurance policies, helping business owners identify potential coverage gaps and take appropriate action to protect their operations.

Understanding Machinery Breakdown Insurance

Before examining exclusions, it's essential to understand what machinery breakdown insurance typically covers. This specialized coverage protects businesses against sudden and accidental mechanical or electrical breakdown of equipment. Standard coverage includes repair or replacement costs, business interruption losses, and sometimes expediting expenses to speed up repairs.

However, the devil is in the details. Policies contain extensive exclusion clauses that significantly limit when and how coverage applies. These exclusions exist to prevent coverage of predictable, preventable, or uninsurable losses.

Common Machinery Damage Exclusions

Wear and Tear

The most fundamental exclusion in machinery insurance is wear and tear. Insurers will not cover damage resulting from normal operational deterioration over time. This includes:

Gradual deterioration of components through regular use, rust, corrosion, oxidation, erosion, and general aging of equipment. If your manufacturing press gradually loses efficiency due to years of operation, replacement costs fall outside coverage.

Consumable parts such as filters, belts, hoses, lubricants, coolants, and batteries are typically excluded. These items require regular replacement as part of normal maintenance and are considered operational expenses rather than insurable losses.

Progressive damage that develops slowly over weeks or months rather than occurring suddenly is excluded. For example, bearing wear that gradually worsens until equipment fails would not be covered, whereas a bearing that suddenly seizes due to contamination might be.

Lack of Maintenance

Insurers expect policyholders to maintain equipment according to manufacturer specifications. Exclusions related to maintenance include:

Inadequate servicing where equipment hasn't received required inspections, lubrication, adjustments, or component replacements as specified by the manufacturer. If your HVAC system fails because filters weren't changed for two years, the claim will likely be denied.

Deferred maintenance occurs when known issues are ignored or repairs postponed. If warning signs were present but not addressed, resulting damage may be excluded.

Improper maintenance using incorrect lubricants, unauthorized parts, or unqualified technicians can void coverage. Following manufacturer guidelines is essential for maintaining insurance protection.

Design Defects and Manufacturing Flaws

Most policies exclude losses arising from inherent defects in design, materials, or workmanship. This includes:

Original manufacturing defects present when equipment was new. Insurers argue these should be addressed through manufacturer warranties rather than insurance claims.

Design flaws that make equipment inherently prone to failure. If a particular model has a known design weakness, damage resulting from that flaw may be excluded.

Material defects where substandard components were used in manufacturing. These issues should be pursued with the manufacturer or supplier rather than through insurance.

However, there's an important distinction: while the defective part itself isn't covered, resulting damage to other equipment may be. If a defective motor bearing causes the motor to overheat and damage connected machinery, the consequential damage might be covered even though replacing the defective bearing is not.

Improper Installation and Commissioning

Damage resulting from incorrect installation or commissioning is typically excluded:

Installation errors such as improper alignment, incorrect electrical connections, inadequate foundation work, or failure to follow manufacturer installation guidelines can void coverage.

Commissioning failures where equipment wasn't properly tested, calibrated, or run-in before full operation may exclude subsequent damage.

Unauthorized modifications made during or after installation that deviate from manufacturer specifications typically void coverage.

Operator Error and Misuse

Human error represents a significant exclusion category:

Deliberate misuse or operating equipment beyond rated capacity is excluded. Running machinery at excessive speeds, loads, or temperatures voids coverage.

Lack of training where operators haven't received proper instruction may exclude resulting damage. Businesses must demonstrate that personnel are qualified to operate equipment.

Negligent operation including ignoring warning lights, alarms, or obvious signs of malfunction can result in claim denial.

Unauthorized operation by unqualified personnel typically excludes coverage. Only trained, authorized individuals should operate covered machinery.

Experimental or Testing Operations

Most policies exclude damage occurring during:

Testing and commissioning of new equipment before it enters regular service. Separate commissioning insurance may be required.

Experimental processes using equipment for purposes other than normal operations or testing new procedures.

Research and development activities where equipment is used in non-standard ways.

Electrical Disturbances

While sudden electrical damage may be covered, many electrical-related exclusions exist:

Power surges and spikes from external sources may be excluded unless caused by lightning. Voltage fluctuations from utility companies often fall outside coverage.

Brownouts and voltage drops that cause equipment damage may be excluded. Businesses in areas with unstable power should consider additional protection.

Harmonics and power quality issues resulting from the electrical installation itself are typically excluded.

Short circuits caused by rodents, moisture, or contamination may be excluded depending on circumstances.

Contamination and Foreign Objects

Damage from contamination often falls outside standard coverage:

Coolant or lubricant contamination that causes machinery damage may be excluded if resulting from inadequate maintenance or monitoring.

Foreign object damage where debris, tools, or materials enter machinery may be excluded if proper safeguards weren't in place.

Dust and environmental contamination in environments where protective measures should have been implemented may void coverage.

Freezing and Environmental Conditions

Environmental damage exclusions include:

Freeze damage to water-cooled equipment when facilities aren't properly heated or protected during cold weather.

Excessive heat or humidity beyond equipment specifications, particularly if environmental controls were inadequate.

Corrosive atmospheres where equipment operates in environments for which it wasn't designed or protected.

Cyber and Electronic Data

Modern machinery with computerized controls faces additional exclusions:

Software failures including bugs, glitches, or compatibility issues are typically excluded.

Cyber attacks that cause machinery malfunction or damage generally fall outside standard machinery breakdown coverage.

Data corruption or loss affecting machinery operation is usually excluded. Separate cyber insurance is required.

Programming errors in CNC machines, robots, or automated systems may exclude resulting damage.

Consequential Losses Beyond Policy Scope

While machinery breakdown insurance often includes business interruption coverage, certain consequential losses are excluded:

Loss of market or contracts resulting from inability to fulfill orders may exceed policy limits or fall outside coverage.

Penalties and liquidated damages for late delivery or non-performance are typically excluded.

Loss of anticipated profits from new ventures or contracts may not be covered.

Reputation damage and loss of goodwill generally fall outside machinery policies.

War, Terrorism, and Nuclear Risks

Standard exclusions found across most insurance policies apply:

War and military action of any kind excludes coverage for resulting machinery damage.

Terrorism may be excluded or require separate coverage depending on policy and location.

Nuclear incidents including radiation or radioactive contamination are universally excluded.

Intentional Acts and Criminal Activity

Damage resulting from intentional or criminal acts is excluded:

Deliberate damage by the insured, employees, or anyone acting on their behalf voids coverage.

Theft or vandalism may be excluded from machinery breakdown policies, though covered under property insurance.

Fraudulent claims not only result in denial but may void the entire policy.

Excluded Equipment Types

Certain equipment categories are commonly excluded from machinery breakdown policies:

Vehicles including cars, trucks, and mobile equipment are typically excluded and require separate auto insurance.

Portable tools and handheld equipment usually fall outside coverage.

Computer equipment may require separate electronic equipment insurance.

Underground piping and structures often need specialized coverage.

Prototype or custom-built equipment may be excluded or require special underwriting.

Geographic and Temporal Exclusions

Off-premises coverage may be limited or excluded. Equipment temporarily removed from insured locations might not be protected.

Transit damage while equipment is being moved or transported typically requires separate inland marine coverage.

Storage damage to idle or mothballed equipment may be excluded after specified periods.

How to Address Coverage Gaps

Understanding exclusions is the first step. Taking action to address gaps is equally important:

Review policies carefully with your insurance broker to identify specific exclusions in your coverage.

Implement preventive maintenance programs to eliminate maintenance-related exclusions and demonstrate due diligence.

Maintain detailed records of all maintenance, repairs, training, and operational procedures to support potential claims.

Consider endorsements that buy back certain exclusions for additional premium.

Purchase supplementary coverage for excluded risks that pose significant exposure to your business.

Implement risk management practices including operator training, environmental controls, and equipment monitoring systems.

Work with qualified contractors for installation, maintenance, and repairs to avoid exclusions related to workmanship.

The Importance of Policy Review

Machinery damage exclusions vary significantly between insurers and policy forms. What's excluded in one policy might be covered in another. Regular policy reviews ensure your coverage keeps pace with:

Equipment changes as you acquire new machinery or retire old equipment.

Operational changes when you modify processes or enter new markets.

Regulatory changes that may affect coverage requirements or exclusions.

Market developments as insurers introduce new coverage options or modify exclusions.

Conclusion

Machinery breakdown insurance provides valuable protection for businesses dependent on equipment, but exclusions significantly limit coverage. Understanding what's NOT covered enables business owners to make informed decisions about risk management, maintenance practices, and supplementary insurance needs.

The key to adequate protection lies in thoroughly understanding your policy exclusions, implementing robust maintenance and operational procedures, maintaining detailed documentation, and working with experienced insurance professionals to structure comprehensive coverage.

Don't wait for a claim denial to discover coverage gaps. Review your machinery insurance exclusions today and take proactive steps to protect your business from uninsured losses. The cost of addressing exclusions through preventive measures is invariably less than bearing the full financial impact of excluded damage.

Sources: User Context summary