Dropped Object Barrier Systems: Selection Guide

This article is Part 3 of our Dropped Object Prevention series. Read Part 2: Top 10 Causes of Dropped Objects on Industrial Sites

Implementing Drops Prevention

When it comes to the reality of preventing Dropped object ("drops") incidents, it's important to know and understand how and why they occur. Once armed with this knowledge, the task of mitigating risks becomes significantly easier.

Across multiple industries, especially those in the energy sector, the risk of objects falling from height is exponentially higher due to the kind of work that is being undertaken. This includes regular maintenance, tasks that can be potentially dangerous if not done correctly and influential and unavoidable environmental factors.

Tools and handheld items can easily fall, as can heavier fixtures located at height such as lights, CCTV cameras and all other high-placed equipment. The heavier objects tend to fall most commonly as a result of factors that cannot actively be controlled, such as vibration, corrosion and general wear. Smaller, handheld items fall as result of human error and while this is easier to control, workers don't drop or dislodge tools intentionally. It is therefore paramount that all possible measures are taken across all areas to avoid these incidents which, although very different, can have the same negative and potentially devastating outcomes.

Effective dropped object prevention relies on a dedicated program encompassing multiple processes and solutions, the following section focuses on one solution in detail: Barrier systems.

 

Barrier Systems and What Regulations and Industry Standards Require

Here we will take a closer look at one of the core engineered solutions available to mitigate dropped objects - safety barrier systems. Often referred to in industry guidelines as "barricades" or "safety barricades," these solutions are essential for comprehensive worksite safety. To date, there has not been a detailed guide on the best practice applications of this technology. 

Beyond general best practices, barrier systems are often critical for strict regulatory compliance. For instance, OSHA standard 1910.29(k)(2)(i) mandates that ” Where tools, equipment, or materials are piled higher than the top edge of a toeboard, paneling or screening is installed from the toeboard to the midrail or top rail, for a distance sufficient to protect employees below from the falling objects.” 

Additionally, DROPS Reliable Securing, which was originally developed for the oil and gas sector but has now formed the basis for best practice across other industries, states: 

"Safety barricades and mesh systems may be applied to reduce potential for items to fall through guard rails. These should be of suitable materials, incorporate appropriate securing features and be installed and maintained in accordance with manufacturer's recommendations."

Two requirements follow directly from this guidance. First, suitable materials: components must withstand the environmental conditions of the site, including impact, vibration, corrosion, heat, and chemical exposure without degrading over time. Second, appropriate securing features: attachment mechanisms must be purpose-built to keep the barrier fixed to the guardrail under dynamic load, not improvised fastenings or generic hardware. These two criteria form the baseline for evaluating any barrier solution.

Here we will expand on this regulatory and industry guidance to help facility and site managers identify the best barrier systems and understand how these barricades can be used most effectively as part of a broader dropped objects prevention programme. 

 

What is a Drops Prevention Barrier System?

Drops prevention barrier systems attach along the inside of guardrailings on stairways, elevated walkways and raised working platforms, covering the gaps to prevent objects from falling through. These objects can include tools, handheld equipment, and loose fixtures or machinery components.
A robust barrier system will also prevent items that have dropped from potentially ricocheting further, by absorbing the force of a falling object. This is particularly important because items that drop can often ultimately strike a worker from unexpected directions.

Where Should Barriers Be Installed?

There are three main Drops risk areas where installing a barrier system is most effective: walkways, stairways and conveyers.

Walkways & Working Platforms
Elevated walkways and working platforms are high-risk Drops areas, due to large gaps between the guardrailings, and a high likelihood of personnel walking below. Walkways also serve as arteries for personnel, who often carry untethered tools and equipment throughout the facility, creating Drops risks. Barrier systems are a crucial part of Drops prevention, as walkways are often extensive and will be placed over multiple levels.

Stairways
As a point of transition within a facility, a stairway presents a significant Drops risk. Additionally, when personnel are using stairways, they may carry tools or equipment in one hand while using one hand on the handrail, further increasing Drops risks.
Barrier systems should therefore be installed along the guardrailings at the sides of the stairs to prevent objects being dropped through. Where the gaps between steps are large, it is worthwhile to consider installing barriers on the underside of stairs too.

Conveyer & Machine guards
If an object falls from or comes off a conveyer belt, it can result in significant injury to personnel. Additionally, if a tool is dropped into a turbine or machinery, it may be unsafe to retrieve, or cause damage to critical equipment. A barrier system will help to mitigate these risks.
The correct installation of a barrier system is vital, but what characteristics need to be considered when choosing a barrier?

 

 

How the Solutions Compare

The most commonly deployed barrier systems vary in how well they meet DROPS criteria. What follows is an assessment of each option, from least to most capable, measured against the two requirements set out in the previous section: suitable materials and appropriate securing features. 

Flexible Mesh Netting

Flexible mesh netting is constructed from connected strands of fibre or PVC and attached to rails on walkways at height. It is fast to install, requires minimal tools, and has a low upfront cost, making it a practical choice where procurement timelines are short. 

Against DROPS criteria, it falls short on both counts. UV resistance is limited to approximately 12 months, and low impact and heat resistance means the material degrades quickly in demanding environments. It is also typically attached using cable ties, which do not meet the standard of purpose-built securing features. Flexible mesh netting is best suited to short-term or temporary applications, rather than a long-term dropped objects prevention programme. 

Bolted Metal Fencing 

Bolted metal barriers are retrofitted to existing guardrails using mounting brackets and, in many cases, hot works. Installation requires specialist tradesmen and a significant level of effort. The solution is robust in terms of impact and fire resistance and can last up to five years with regular maintenance.

There are, however, notable compliance considerations. A large aperture means smaller objects and debris can still pass through, which works against the DROPS requirement for suitable materials. Bolted connections also introduce a secondary dropped object risk, as loose bolts and components can fall during and after installation.

The solution is not considered compliant with offshore best practice, and corrosion over time, particularly from galvanic reactions with metal railings, adds ongoing maintenance costs across the product lifecycle.

Expanded Metal

Expanded metal barriers are formed from sheet metal that has been cut and stretched into a regular mesh pattern. Installation is via welding and hot works, which allows the barrier to withstand high-impact loads from multiple directions. 

 

Next in this series: Tool Tethering Best Practice for Working at Height