Advancing Road Safety and Construction

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Steel barrier protects people and plant at Coke
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Principal: Coca-Cola Amatil (NZ) Ltd
Location: Storage and distribution centre Mt Wellington
Product: Flexrail™ W-Beam Galvanised Steel Highway Barrier


Coca-Cola Amatil New Zealand had invested around $80 million dollars on a state of the art (36,000 pallet position) storage and distribution centre in Mt Wellington and were only 2 months from the scheduled opening of the centre, when they struck a major hurdle in getting the factory open on time.  

An overseas company had been commissioned to supply a safety barrier system for use inside the factory to provide safe walkways for staff and to protect precious machinery from the threat of moving fork hoists.  

The installation of the barrier began, but Coca-Cola Amatil was not happy with the quality and cost of the system being installed. With the new centre being fully automated, (ie being capable of automatically assigning the oldest product to be distributed first from their stock) they could not afford in any way to have a ‘break in the chain’ through a fork hoist damaging machinery or causing injury to staff.  

With two months until the scheduled opening, Cameron Marsh, Warehouse Technical Support Manager from Coca-Cola, was working against the clock, when someone suggested the use of steel road barrier. After searching the web, Cameron found the CSP Pacific website and contacted Andy Holmes, Sales Engineer for CSP Pacific, to see if they could help with a solution to the problem. 

After checking the site and discussing Coca-Cola’s requirements with Cameron Marsh, a system was designed with approximately 1m high double rail Flexrail™ - a galvanised steel road safety barrier and the most commonly used crash barrier in New Zealand. “Cameron wanted decent gaps at the bottom and through the middle for visibility and higher protection,” says Andy Holmes. “This fits perfectly with Flexrail™’s specifications and at 2.7mm thick - as opposed to the 1mm thick initial option - Flexrail™ gives Coca-Cola more than enough protection for staff and machinery. This rail is designed to handle an impact from a 2 tonne truck travelling at 100kms/hr!”

“We had to design and manufacture non standard posts for this installation and, with a total of over 440 metres of rail and a lead time of only three weeks, the pressure was on”, says Andy Holmes. “But we achieved our deadline and the factory opened at the end of September on schedule!”

“Flexrail™ is a cost effective robust product that will stand the test of time for Coca- Cola”, added Andy Holmes. “Not only is the whole facility a design innovation, with the pallet racking being part of the structure of the building, but the Flexrail™ solution we provided Coca-Cola was also a first in this type of situation for CSP Pacific. In fact we see it as a growth area for a very versatile, economical product.”


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