Article: Exclusion zone mesh: setting up compliant exclusion zones on Australian worksites

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May 13, 2026AS/NZS 1319

Exclusion zone mesh: setting up compliant exclusion zones on Australian worksites

An exclusion zone is an area of a worksite from which all persons not involved in a specific activity must be excluded for the duration of that activity. It is not a suggestion, a courtesy marker, or a preference — it is a control measure required under the WHS Act wherever a work activity creates a risk of harm to persons in the vicinity.

Exclusion zone mesh is the physical marker that makes the boundary of that zone visible, continuous, and clearly signed. Getting it right means the zone works as intended. Getting it wrong — an undersized zone, gaps in the mesh, inadequate signage — means the control measure exists on paper but not in practice.

When exclusion zones are legally required

The WHS Act and regulations identify specific activities that require formal exclusion zones as part of their risk management. These include:

Work at height and overhead work — Any work at height where falling objects present a risk to persons below requires an exclusion zone sized to capture the potential fall zone. AS/NZS 1891 (industrial fall arrest systems) and the Model Code of Practice for Managing the Risk of Falls at Workplaces both address overhead exclusion requirements.

Crane and rigging operations — The crane's working radius, the load path, and an additional buffer for load swing must be incorporated into the exclusion zone. The crane operator has authority to halt lifts if persons enter the exclusion zone. This is documented in the lift plan.

Excavations and trenches — The exclusion zone around an open excavation must prevent persons from approaching close enough to be at risk from a collapse of the edge. The required distance depends on soil type, excavation depth, and support system.

Energised electrical work — Work on or near energised electrical infrastructure requires exclusion zones defined by the voltage level. The approach limits specified in state electrical safety legislation (which vary by state and voltage) define the minimum exclusion distance.

Explosive and demolition operations — Blasting and controlled demolition create specific exclusion requirements, typically defined by the explosives engineer or demolition contractor as part of the blast plan.

Chemical spills and hazmat incidents — Emergency services establish exclusion zones at chemical incidents. On industrial sites where hazardous chemical releases are a foreseeable event, pre-planned exclusion zones should be part of the emergency response plan.

Sizing the exclusion zone

The exclusion zone must be large enough to protect persons from the hazard, not just large enough to look like a zone. Common errors include:

Sizing to the task area, not the hazard zone — the zone around a grinder on a platform needs to extend to where grinding sparks can travel, not just to the edge of the platform
Not accounting for dynamic hazards — a crane exclusion zone that does not include the potential swing radius of the load is undersized
Ignoring rebound or bounce zones — dropped or falling objects do not always fall vertically; the exclusion zone must account for the realistic fall trajectory on the specific site geometry

The supervisor or responsible person for the work activity should determine the exclusion zone size as part of the job safety analysis (JSA) or take 5 process before work begins.

Mesh installation requirements

Exclusion zone mesh must be:

Installed before work begins — not retrofitted after the activity has started
Continuous — no gaps that a person can walk through without realising they have entered the zone
At appropriate height — typically 900mm minimum, sufficient to be seen by an approaching person
Clearly signed — with hazard identification explaining why the zone exists and prohibiting unauthorised entry
Maintained for the duration — mesh that has been moved, knocked down, or damaged must be reinstated before work continues

Signage on the mesh should identify the hazard in plain language: "Exclusion zone — overhead work in progress — no entry" is more useful than "Danger — do not enter" because it tells the approaching person why the zone exists and what the hazard is.

Who can enter

An exclusion zone permits entry only to persons directly involved in the work activity, who are aware of the hazards, and who have the controls in place that make their presence safe. This should be defined in the JSA. In most cases, the exclusion zone should be empty of everyone except the workers directly performing the activity.

For zones around energised electrical equipment, additional entry requirements (licences, permits to work, escort requirements) apply under state electrical safety legislation.

Removing the exclusion zone

The exclusion zone must remain in place until the hazard is controlled. For a single lift, that means until the load is set down and the rigging is recovered. For overhead work, until all workers and their tools are clear of the overhead area. For excavations, until the trench is backfilled or the permanent shoring is in place.

Premature removal of an exclusion zone is a WHS Act breach. Responsibility for the zone stays with the PCBU who established it.

Frequently asked questions

Does an exclusion zone need to be fenced, or is mesh sufficient? For most work activities, mesh is sufficient. Where the hazard is severe (high-energy blasting, live electrical work, structural demolition), a more substantial physical barrier may be required. The appropriate barrier type is determined by the risk assessment for the specific activity.

Can I use bunting (barrier tape) instead of mesh? Barrier tape (bunting) is visible but provides no physical resistance to entry. It is appropriate for low-risk demarcation and short-duration activities where the risk of inadvertent entry is low. For activities with serious consequences if the zone is breached, mesh or solid barriers are more appropriate because they require a deliberate physical act to cross.

What signs must be on an exclusion zone? At minimum, each entry point to the zone must be clearly signed with the nature of the hazard and a prohibition on entry for unauthorised persons. High-visibility signs at 10-15 metre intervals along the mesh reinforce the zone for persons approaching from angles where they cannot see the entry signs.

Who is responsible if someone enters an exclusion zone and is injured? The PCBU who established the work activity has the primary duty to ensure the zone is effective. If the zone was properly established and signed and the person entered without authorisation, this does not extinguish the PCBU's duty but it may affect the relative liability assessment. Adequate signage, continuous mesh, and a record of the zone establishment (including the JSA) are the PCBU's evidence of compliance.

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