Falling objects are one of the quieter risks in a warehouse. A carton that slips off the back of a shelf, or a pallet that tips from a mezzanine edge, can cause serious injury. Most of the time nothing happens, which is exactly why the risk is easy to overlook. Fall protection mesh is a simple, low-cost way to reduce it.

Here is what to know about fall protection mesh in Sydney and where it is used, what to look for in a system and how it fits with the rest of your warehouse safety plan.

What it is

Fall protection mesh is a steel panel or screen, usually made from welded wire, that is fixed to racking, shelving or mezzanine structures. It acts as a barrier to stop items from falling through, over or behind the structure. The wire grid lets people see through it, keeps airflow and light moving and lets sprinkler water pass, while still holding back loads and, in some applications, people.

Panels are normally modular and bolt or clip onto the structure. This makes them easy to install on new systems and, in many cases, to retrofit to existing ones.

Where it is used

Back of pallet racking. Where racking sits above an aisle, a walkway or a work area, mesh on the back of the bay stops loads from pushing through to the other side. It is especially important where racking backs onto a pedestrian zone, an office or a loading area.

Between racking runs. In back-to-back arrangements, mesh between the two rows prevents a pallet from being pushed from one side into the other. It also stops small items from falling into the gap between rows.

Mezzanine edges. Open edges on raised platforms need protection against people and loads falling. Mesh panels and gates give a secure perimeter while still allowing visibility across the floor.

Pallet gates. Where goods are loaded onto a mezzanine, safety gates let a pallet in while keeping the opening closed at other times. A well-designed gate keeps a barrier in place at all times, either behind the pallet or in front of it.

Walkways and machine guarding. Mesh can also be used to separate workers from moving equipment or to enclose cages and storage areas. In some sites it forms secure storage compounds for valuable stock or hazardous items.

Why it matters

Workplace safety laws expect employers to manage risks that can reasonably be foreseen. Falling objects and falls from height are well known hazards, so a well-designed barrier is part of showing that you have taken action. Mesh also helps protect stock from damage and reduces the chance of expensive incidents, including injuries, lost time and product loss.

There is a practical benefit as well. When staff know the area behind a rack is protected, they work with more confidence, and the risk of someone being struck from above is reduced.

What to look for in mesh systems

• Strength. Panels should be rated for the loads and impacts they may face.
• Fixing. Mesh should connect securely to uprights or frames, with no gaps that items can slip through.
• Aperture size. The openings should be small enough to stop the items you store. Small parts need a finer mesh than large cartons.
• Finish. Powder coat or galvanised finishes give better durability and visibility.
• Compatibility. Panels need to suit your racking profile or mezzanine design.
• Height. The panel should extend high enough to catch items at the top of the bay.

Mesh and sprinklers

Fire protection is a key concern in warehouses. Mesh with open apertures generally allows sprinkler water to pass, while solid panels can block it. If your site has sprinklers, discuss any barriers with your supplier and fire professional so that protection does not compromise fire safety.

Mesh on mezzanines

On a mezzanine, guardrails and gates work together. The rail protects people from falling, while the mesh stops small items from dropping through the gaps. At loading points, a swing gate or sliding gate lets pallets in and out while keeping the edge protected. The design should never leave the opening unguarded while a load is being moved.

Edge protection on raised floors is a safety-critical item, so it should be designed to the relevant standards and installed by experienced people.

Combine with good practice

Mesh is one layer in a safety approach. Keep load signs visible, avoid overloading, and train staff to place items safely. Include mesh in your regular inspections so any damage or loose fixings are fixed quickly. A panel that has been struck or bent may not hold the load it is meant to.

Plan it from the start

It is easier and cheaper to include fall protection when a system is designed than to add it later. If you are installing a mezzanine or a new racking layout, discuss protection in your first meeting. Retrofitting is possible, but it can be harder when the structure has already been built or loaded.

Common questions

Is mesh required on all pallet racking? Not always. It depends on the layout, the stock and who is nearby. A risk assessment will show where it is needed.

Can mesh be added to existing racking? In many cases yes, as long as the panels match the frames and the system can carry the extra weight.

Does mesh stop small items? It depends on the aperture. Choose a mesh that suits the smallest items you store.

DRS Racking Solutions supplies and installs fall protection mesh as part of its racking and mezzanine work in Sydney and NSW. Details are available at drsrackingsolutions.com.au.