Steel fence posts left uncovered on construction sites pose a costly risk that many contractors underestimate, according to Anthony Burr, founder of Safety Pickets, Inc. Burr, a former concreter who worked around exposed star pickets—the Australian term for steel T-posts—invented a reusable steel cap after years of witnessing preventable injuries. He argues that the low upfront price of plastic caps is misleading once liability, labor, and replacement costs are factored in.
Burr points to a case in Australia where posts were left uncovered and someone fell onto one, resulting in a $115,000 fine. “That’s just a fine,” Burr said. The figure excludes site shutdowns, medical bills, and legal claims. Even minor injuries add up: a worker needing stitches for a shin cut leads to medical costs, paid time off, and lost productivity. “It can go into the tens of thousands easily,” Burr said.
Plastic caps also carry hidden replacement costs. They break, blow away, and degrade in sunlight. Burr notes that covering 1,000 posts over five years with reusable steel caps saves 60 percent compared to continually rebuying plastic ones. Steel caps do not rust and likely outlast the posts themselves. Labor is another overlooked expense: plastic caps must be installed and removed each time posts are used, taking about half an hour each way. “So it adds up quite quickly that the plastic caps aren’t actually cheaper,” Burr said. The company details these savings on its sustainability page.
Liability extends beyond a contractor’s own crew. If trespassers—even intoxicated ones—are injured on exposed posts, property owners can still face lawsuits. “They shouldn’t have, but they have every right to be able to sue,” Burr said. For US contractors, where injury claims are common, this exposure is significant.
Burr advises contractors to calculate the cost of replacement caps, labor hours, and a single injury against the one-time cost of reusable steel caps. “If something can go wrong, then it will,” he said. “So just the labor costs, the liability, the headaches, and the stress are all hidden costs. Hidden costs that will add up over time. You may not have to outlay it. But it catches up very quickly.” Safety Pickets, Inc. designs and manufactures a patented, reusable steel safety cap for star pickets and T-posts, currently sold across Australia and expanding into the US market. Learn more at safetypickets.com.
This article is intended for informational purposes only and does not constitute legal, financial, or investment advice. The views and opinions expressed herein reflect those of the individuals quoted and do not represent an endorsement of any company, product, or service mentioned. Readers should conduct their own due diligence and consult qualified professionals before making any investment decisions. Disclosure: Individuals or companies mentioned may have a commercial relationship with KeyCrew.
