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- ABB Australia
ABB Australia
- Location: Sydney, Australia
- Visit: https://new.abb.com/au
The Problem
ABB is a leading global technology company that operates in electrification, automation, and motion. Its Moorebank head office in Sydney contains more than 27,000m² of office and factory space and accommodates over 500 employees. The factory plays a critical part in ABB’s electrical distribution, switchgear, and equipment testing operations.
As part of ongoing safety improvements within the facility, ABB turned to Barrier Group. During an on-site assessment, conducted by a dedicated Barrier Group Account Manager, it was clear ABB’s industrial-grade facility presented a unique risk profile.
The following was identified during the walkthrough:
- High-risk operational zones: Forklifts regularly operated adjacent to high-voltage electrical testing equipment and employee workstations, with some testing activities reaching up to 70,000 volts. ABB required a barrier system that would clearly delineate these areas, provide impact protection from material handling vehicles, and present a professional appearance for customers visiting the facility.
- Controlled access storage zones: Various areas of the facility were designated for the storage of electrical equipment and components, requiring controlled access for both pedestrians and forklifts throughout the day. A solution was needed to securely define these zones while allowing safe, efficient access for picking, storage, and ongoing operational activities.
- Active machine zones: Conveyor belts, lathes, drill presses, cut-off saws, and folder presses operated continuously throughout the facility, requiring physical segregation to prevent unauthorised access, protect personnel from moving machinery, and reduce the risk of collisions involving material handling vehicles.
- Temporary holding bays: Designated areas of the facility were used as temporary holding bays for electrical equipment awaiting deployment. ABB required a modular barrier system that could be quickly installed and reconfigured to accommodate changing operational requirements without disrupting floor workflow.
The Solution
Working closely with ABB’s team, the Barrier Group Product Solutions Team worked with the client to design and engineer a tailored, compliant, and future-ready machine guarding fit-out aligned with the operational demands of each zone. ISF Panels were chosen based on the unique requirements of each area including:
For high-risk operational zones:
✔ ISF - Polycarbonate Infill Panels were chosen for their transparent design and durable construction. Polycarbonate infill machine guarding panels are ideal for when complete visibility is needed while offering additional protection from debris or contamination. Additionally, the transparent panels allowed visitors to be safely shown the testing areas/process from a fully segregated viewpoint.
✔ A combination of ISF - Polycarbonate Cantilever Sliding Doors and Single Hinged Doors with Spreader Bars were installed to create safe, controlled access between workstations. Cantilever Sliding Doors were selected for areas with limited swing clearance or wide openings, providing a space-saving solution without the need for ground tracks. Hinged doors with spreader bars created safe access points while allowing electrical cables to be routed overhead.
✔ ISF – Welded Mesh Infill Panels were used in adjacent ‘less-active’ testing areas of the facility, offering segregation and protection from moving material handling vehicles.
For active machine zones:
✔ ISF - Welded Mesh Infill Panels were selected to prevent reach through, reach over and reach under to hazardous machines such as conveyor belts, lathes, drill presses, cut-off saws, and folder presses.
For storage zones:
✔ ISF - Welded Mesh Infill Panels were used to delineate the perimeter of the different storage areas.
✔ A combination of ISF - Welded Mesh Twin Hinged Doors and Cantilever Sliding Double Doors were installed to suit the varying access requirements. Sliding double doors were specified for larger storage and racking areas to accommodate vehicle access, while single hinged doors with spreader bars provided controlled pedestrian entry. In one storage area housing robotic equipment, a custom hinged door with a lockable standard handle was designed and manufactured to provide secure, controlled access for authorised workers only.
✔ ISF - Sheet Metal Infill Panels were installed to partition non-customer-facing storage areas. Additionally, the magnetic surface allowed ABB to attach safety procedure notices and signage directly to the barrier.
For temporary holding bays:
✔ PortaGuard Maxi Expandable Barriers with Drop-Bolt Kits were installed in both post-mounted and freestanding configurations to create adaptable storage and work zones. Easily reconfigured to suit changing operational requirements, the barriers provide flexible segregation, while the drop-bolts secure them in position to create a stable, semi-permanent perimeter when required.
All panels and doors were paired with ISF Posts with Central Case Plates. Posts were finished with a safety yellow powder coating for long-term durability. This is the most commonly specified post and is adaptable to most applications.
“We’ve been using the Industrial Safety Fencing range for over 16 years. The product is good, reliable, and strong. With new products and material selection continually being added to the range, for example, the clear polycarbonate, we can now highlight what we do to customers, providing our facility with a bit of a wow factor whilst also keeping everyone safe.”
– Ian Upton, Service Production Manager
For ABB, working with Barrier Group to design, manufacture, supply, and install a fully integrated safety solution made for a seamless process from initial site assessment through to sign-off.
Barrier Group’s turn-key approach ensured minimal operational disruption throughout, with the entire fit-out delivered on schedule across ABB’s live-working facility.
