Plastic caps for steel fence posts are ubiquitous on construction sites because they are inexpensive. But Anthony Burr, founder of Safety Pickets, Inc., argues that the low upfront price is misleading once the full costs of cap failure or loss are considered. Burr, who spent years as a concreter working around exposed steel star pickets (the Australian term for steel T-posts), invented a reusable steel cap after witnessing the dangers firsthand. His cost comparison reveals a stark contrast between initial savings and potential liabilities.
Covering 100 posts with Safety Pickets' steel caps costs roughly $250 to $300, and the caps can be reused indefinitely. In contrast, Burr cites an Australian case where uncovered posts led to a fall and a $115,000 fine—a figure that excludes site shutdown, medical bills, or legal claims. For contractors, the gap between a few hundred dollars and a six-figure penalty is difficult to ignore. Even minor injuries, such as a cut shin requiring stitches, can cost tens of thousands when factoring in medical expenses, lost workdays, and compensation.
Beyond liability, plastic caps carry ongoing replacement costs. They break, blow away, and degrade in sunlight and rain. According to Burr, covering 1,000 posts over five years with reusable steel caps yields a 60 percent saving compared with continually rebuying plastic ones. Steel caps do not rust and likely outlast the posts themselves. Labor is another hidden expense: plastic caps must be installed and removed each time posts are used, consuming about half an hour per operation. "It adds up quite quickly that the plastic caps aren't actually cheaper," Burr said.
The company details how reusable steel caps reduce replacement and waste on its sustainability page. Liability also extends beyond one's own crew. Trespassers, including those who are intoxicated, can still sue if injured on an exposed post. "They shouldn't have, but they have every right to be able to sue," Burr said. This exposure is particularly relevant for US contractors and property owners, where legal claims after injuries are common.
Burr advises contractors to calculate total costs: replacement caps over several years, labor hours for installation and removal, and the realistic cost of a single injury. Comparing that to the one-time cost of reusable steel caps often clarifies the decision. "If something can go wrong, then it will," Burr 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." 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.
