Tomago Aluminium Company Pty Ltd

Tomago Aluminium Company Pty Ltd

Tomago Aluminium is Australia’s largest aluminium smelter and has been operating 24 hours a day since 1983. Tomago Aluminium company is an independently managed joint venture. Joint Venture partners are Rio Tinto Alcan, CSR and Hydro Aluminium. The owners provide raw materials to Tomago that are converted to aluminium at the Tomago plant. The product is supplied back to the owners who then take it to market.

The Problem

Tomago Aluminium’s existing industrial gates, operating in their Hunter region based smelter, were deemed no longer suitable and in need of an upgrade. The existing gates were not long enough to cover the distance of the factory floor. This was allowing cars, and other factory vehicles, through-access even when the gates were in the closed position. It had become a concerning workplace safety situation.

The Solution

There were no suitable ‘off the shelf’ options available, so the Barrier Group design team worked on customising our existing industrial manual swing gate to allow for the extra length and mobility required. By installing a heavy-duty hinge within the gates boom, and adding extra boom length, the desired outcome was able to be achieved. Finished with a simple to use slot-latch system which securely locks the gates together in the middle when in use.

The Challenges

The size and span of the space needing to be protected required specific calculations to ensure the customised gate would be effective when operational. When the prototype hinge was tested it lacked the strength required to safeguard the gates functioning longevity. A heavier-duty hinge was created, successfully tested and installed. Due to the width of the factory floor, one single gate was not going to be feasible. The best solution was to simply mirror the customised gate on the opposite side of the space and have the two folding manual swing gates meet in the middle.

Client Response

"The solution designed and manufactured entirely by Barrier Group solved a long running safety issue. The whole upgrade was easy to install and completed in one shift, meaning minimal downtime to production."

Leigh Osmond, Energy Efficiency & Innovation Specialist, Tomago Aluminium Company Pty Ltd


58 - 62 Separation Street,
North Geelong, Victoria, 3215,

1300 55 33 20

1300 92 05 44

Barrier Group

Barrier Group is Australia’s leading industrial safety manufacturer and distributor. Barrier Group designs, manufactures and distributes a wide range of industrial and pedestrian safety products such as bollards, fencing and pedestrian barriers, industrial gates, queue control systems, and traffic and car control products like speed humps, wheel stops and traffic delineators. We supply to all Australian cities including Melbourne, Sydney, Brisbane, Adelaide, Perth, Canberra, Hobart and Darwin, and supply to most overseas locations.

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