Case Study: Australia Post Blacktown

Overview

Verge Safety Barriers, supported by our Impact Polymer Barriers range, recently completed a comprehensive safety barrier installation at the Australia Post parcel distribution facility in Blacktown, NSW. This large-scale project focused on improving warehouse safety and optimising floor space in a high-volume, fast-moving logistics environment.

Project Scope

To meet the specific operational requirements of the site, the Verge team supplied and installed:

• 77 linear metres of Impact Medium Duty Barrier – separating pedestrian walkways from forklift zones
• 82 linear metres of 2 metre high Impact Hy-Wall – providing controlled containment for stacked goods
• 258 linear metres of 4 metre high Impact Hy-Wall – delivering secure barriers for high-bay storage

All barriers were manufactured in Australia and installed by Verge’s in-house team, ensuring consistent quality and minimal disruption to site operations.

Key Challenges

Australia Post Blacktown needed to safely stack stillages up to four high in selected warehouse zones. Without adequate containment, this created safety risks and restricted available floor space for operations.

Our Solution

The Impact Hy-Wall system provided a robust, high-impact barrier that enabled secure vertical storage. The 4 metre high Hy-Wall sections were instrumental in:

• Preventing the risk of stacked stillages toppling
• Creating physical separation between operational zones
• Allowing increased use of vertical space without compromising safety

“By installing our 4 metre high Impact Hy-Wall, we helped the operations team at Australia Post Blacktown safely increase vertical storage and unlock valuable floor space without compromising safety. It’s a great outcome for a high-performance logistics facility.”
– Verge Safety Barriers Project Team

Results Achieved

• Improved site safety through defined vehicle and pedestrian separation
• Increased operational space, unlocking use of over 25% more floor area
• Reduced risk associated with high-density storage
• Fast, professional installation completed with minimal downtime

Australian Made, Purpose Built

All Verge and Impact Polymer Barrier products are proudly Australian made and engineered to suit complex industrial environments. This project demonstrates our ability to provide smart, tailored safety solutions that support performance and protection.