CASE STUDY Dulux HD Steel Hy-Wall

A $500,000 storage problem. Solved for $53,000.

THE CHALLENGE

Dulux’s Virginia manufacturing site was running out of storage space. But the problem wasn’t the building. It was a safety compliance issue they couldn’t work around.

Pallets stacked next to pedestrian walkways created a toppling risk. WHS requirements meant double stacking in those zones wasn’t permitted. With floor space already at capacity, Dulux were left with three options: accept the limitation, relocate the facility entirely, or build a mezzanine floor. The mezzanine quote came in at around $500,000.

They came to Verge looking for another way.

THE SOLUTION

Verge installed 48 linear metres of HD Steel Hy-Wall at 3 metres high along the facility walls adjacent to the pedestrian walkways.

Hy-Wall is a heavy-duty steel panel system that anchors to the floor and braces against the wall, creating a rigid barrier capable of containing pallets stacked at height. With the Hy-Wall in place, the toppling risk was eliminated. The pedestrian walkways remained safe and accessible. And Dulux could now triple stack pallets right up to the barrier line.

Total cost: approximately $53,000.

THE OUTCOME

Dulux went from single stack to triple stack in the same footprint, without relocating, without a mezzanine, and without any structural works beyond the installation itself.

The floor space didn’t change. Storage capacity tripled. And the cost was roughly one tenth of the cheapest alternative they had on the table.

48 linear metres. 3 metres high. A saving of around $447,000.

Facing a storage or compliance problem that seems to need a big solution? Talk to the Verge team.
vergesafetybarriers.com.au