Industry Insights: Moving from Compliance Fear to Operational Confidence in Height Safety

Falls from heights remain one of the leading causes of workplace injuries and fatalities across Queensland. With Workplace Health and Safety Queensland (WHSQ) executing rigorous compliance campaigns targeting construction and maintenance sectors, managing this risk is no longer just a legal obligation—it is a critical operational safeguard.

In this feature, we sit down with Mick Russo, an industry veteran and a key estimator and systems auditor for the height safety division at Aegis Sales & Service (Aegis). From securing iconic theme park roller coasters to managing sprawling government portfolios and mid-market commercial re-roofing projects, Mick shares what it takes to protect workers and bulletproof your corporate liability.

Q: Mick, let’s start with your day-to-day. What is your core focus at Aegis Safety, and how does the team engage with the construction and maintenance sectors?

Mick Russo: I work specifically as an estimator and system auditor within our height safety and roof safety division. My territory spans right across Brisbane, the Sunshine Coast, and the Gold Coast.

At Aegis, our mission is to eliminate the risk of falls by getting actively involved with builders and corporate asset managers during the critical design and construction phases. We supply and install pre-engineered, modular safety systems. This includes everything from permanently mounted anchor points, static lines, and rigid rails to custom walkways, plant-room platforms, and perimeter guardrails.

We don't just supply equipment; we design the structural access frameworks that allow maintenance contractors, HVAC technicians, and facility workers to do their jobs and get home safely.

Q: Queensland is known for its punishing environment—extreme UV radiation, severe storms, and corrosive coastal salt spray. How does our climate affect height safety infrastructure?

Mick Russo: It used to be a massive issue, but modern material engineering has evolved. At Aegis, almost all the permanent fixed systems, anchor points, and static lines we install utilise 316 marine-grade stainless steel. Our walkways and handrail systems are engineered from heavy-duty, anodised aluminium.

This ensures they comfortably withstand the test of time, whether they are baking in the heat out west in Roma or sitting directly on the oceanfront. That said, environmental exposure still demands vigilance. For high-exposure coastal installations, we recommend and implement shorter cleaning and inspection intervals alongside standard compliance checks to ensure the locking mechanisms and structural brackets remain completely uncompromised.

Q: What does a comprehensive Aegis height safety audit look like practically?

Mick Russo: We have a strict rule at Aegis: we do not just "tag and bag." Anyone can walk onto a roof, slap a plastic tag on an anchor point, and walk away; but that doesn't protect a business owner or save a life.

When we conduct a comprehensive site audit, the duration reflects the asset's complexity. A small commercial site might take half a day. A large industrial factory or multi-level plant room facility can take our team four to five days of continuous on-site testing.

We audit systems against two strict benchmarks: current Australian Standards and exact manufacturer specifications. Manufacturers test these systems in highly specific configurations. If a previous contractor used the wrong gauge screw, altered the bracket spacing, or modified a component, the system can fail under the load of a fall. That’s why Aegis never uses external subcontractors. Every single installer and inspector on our team is in-house, manufacturer-trained, and fully certified.

Q: Can you explain the differing lifespans and servicing cadences between fixed installations and personal protective equipment (soft goods)?

Mick Russo: Absolutely, and this is where many asset owners accidentally fall out of compliance.

• Fixed Systems (Static Lines, Walkways, Anchors): These require a mandatory inspection and recertification every 12 months. We log every component, look for stress fractures, corrosion, and structural deformation, and issue formal handover and compliance certificates.
• Soft Goods (Harnesses, Lanyards, Energy Absorbers): Because these are fabric-based and subject to friction, UV degradation, and wearer sweat, they require a mandatory inspection every six months. Furthermore, soft goods have a strict, non-negotiable maximum shelf life of 10 years in the field.

Our system automatically tracks these dates for our clients. We proactively notify them 6 to 12 months before an entire suite of harnesses expires so they can seamlessly phase in new gear without operational downtime.

Q: Aegis manages safety portfolios for some of the biggest and most iconic brands in the country. What are some examples of your specialised capabilities?

Mick Russo: We have an incredibly diverse client footprint. We manage assets for major local government bodies such as Brisbane City Council, Logan City Council, and Moreton Bay City Council. We also hold long-term corporate infrastructure contracts with entities like Q-Build and ALDI supermarkets across Queensland and Northern New South Wales.

One of our most unique partnerships is with Village Roadshow Theme Parks, seeing us work on some of the most iconic theme parks in Australia, including Warner Bros. Movie World, Sea World, and Wet'n'Wild. We engineer and audit customised height safety systems for their major roller coasters and thrill rides.

This involves installing specialised static lines that follow the exact geometric curves of a coaster’s lift hill or stairwell. These systems serve a dual purpose: daily engineering maintenance and emergency patron extraction. If a ride stops unexpectedly, park staff use customised, brand-labelled harnesses and fixed-length lanyards that we engineered specifically to keep patrons completely secure while safely extracting them to the ground.

Q: You also recently secured a massive $1.2M+ heritage re-roofing project at the Old Treasury Casino in Brisbane. How do you navigate height safety when dealing with strict heritage constraints?

Mick Russo: The Old Treasury project (in partnership with FDC Construction at Griffith University) is an amazing, iconic 12- to 14-week undertaking to replace a massive legacy roof safety framework.

Heritage projects always present unique challenges because conservation groups don't want modern visual systems to alter the architectural aesthetic of a historical building. However, we maintain a very firm line as a business: grandfather clauses and heritage aesthetics do not override human safety.

You do not have to sacrifice one for the other. By working closely with heritage architects and engineers, we can design customised, low-profile, or recessed engineering solutions that fully preserve the building's historic character while ensuring full compliance with current WHS standards. Nobody should lose their life because a building needs to look beautiful.

For business owners, corporate boards, or project managers reading this who are looking at their current roof access with a bit of anxiety—what is the first step to gaining operational control?

Mick Russo: Stop waiting for a critical warning sign or an unannounced WHS inspector to arrive at your gate. The risk is too high.

The first step is a clean, transparent assessment. When we deliver an audit report, we don’t just give you a list of failures; we provide a clear risk assessment and a transparent, prioritised roadmap for remedial action. If a system fails, we fast-track the required repairs so you can confidently send contractors onto your roof without exposing your business to catastrophic liability or your workers to physical harm.

Reach out to one of our experts today to get the right height safety solution for your worksite.