Client: Amazon
Location: Western Sydney, Australia
Amazon’s BWU6 Fulfilment Centre marks a major investment in the Australian market. As one of the largest logistics facilities in the region, the site was designed to accommodate high-volume operations while maintaining the highest standards in Health and Safety. The brief was clear: protect people, infrastructure, and assets in a fast-paced, high-traffic environment.
Client Challenges:
- Creating a safe pedestrian walkway throughout the site (dubbed “The Green Mile” due to its size) to separate people from forklifts and other material handling equipment (MHE).
- Preventing Automatic Guided Vehicles (AGV) from impact damage in cage drop zones.
- Safeguarding structural columns from costly vehicle impacts.
- Preventing MHE from entering restricted or vulnerable areas.
- Protecting racking and other structures from the impact of MHE.
- Stopping pallets from falling and causing damage or harm.
Solutions Offered:
Similar to many large distribution companies, Amazon sites have a set layout to ensure that operations can function safely and efficiently across all locations. However, finding the proper safety controls to complement the layout was key.
Our question to the Amazon team, which included the Work Health and Safety Manager, the Supply Chain Program Manager, and the Project Manager, was this: “What purpose is this safety solution serving?” Why? Because too often, the controls aren’t matched to the level of risk or are over-engineered for the situation.
After scoping the site and reviewing the plans, we made recommendations on the solutions that would be most appropriate for each risk area, some of which were adopted as a better alternative to the original plans.
Impact Rating Approved
One of the key factors influencing Amazon’s choice to install the solutions below was that each was tested in compliance with PAS 13 and the latest standard, UNI TS 11886. Unlike other codes of practice, these specifically measure the impact rating of each safety control based on forklift and other MHE impact.
Having this reassurance of solution durability is crucial in a workplace environment where operations run at speed and pedestrians and MHE regularly intersect. Other impact testing methods generally only test against vehicle impact, which is not the most suitable judgment for a warehouse or logistics environment.
Pedestrian & Zone Safety
Initially, the Amazon team thought they needed a double-height Topple Barrier to create their “Green Mile” and separate pedestrians from MHE around the site.
However, following further discussion with our team, they realised the height wasn’t needed to protect pedestrians and MHE in areas that weren’t beside racking.
As a result, they decided to install a flexible, energy-absorbing Single-Height Barrier, which would protect against the specific risks within the area. Matching Swing Gates were also attached to these barriers to encourage pedestrians to pause before walking into the line of traffic and protect them from collisions with MHE.
To prevent Automatic Guided Vehicles (AGV) from colliding with barriers in cage drop zones and causing damage, Amazon opted to install Flex Impact Dock Gates. An alternative to the dock gates used on other Amazon sites, this version was superior in strength, which was particularly beneficial in an area where AGVs are most likely to hit the gate.
Asset & Rack Protection
Pallet fall in double-stacking zones was also a safety concern that needed addressing. Rather than using two solutions, Amazon installed the TB400 Grill Flex safety barrier, which can protect from above as well as from MHE at ground level.
For racking aisle end protection, the TB260 low-height barrier was used instead of bollards (the traditional choice for racking protection) because they were positioned closer to the ground and offered a consistent line of protection from MHE impact.
Infrastructure Safeguarding
At key column positions, BO250F Bollards were installed to defend critical building supports from high-impact contact. Like all safety controls with PAS 13 and UNI ratings, the bollard will absorb the energy and return to its original shape upon impact.
For protecting the AGV hub, Flip kickrails were used for full ground-level protection and to act as controlled stops that prevent collisions and effectively absorb energy in the event of a hit.
The Outcome
Large-scale operations like Amazon’s BWU6 Fulfilment Centre demonstrate how safety and efficiency can coexist without compromise. By collaborating closely with Amazon’s health and safety leaders, we ensured that each solution was fit for purpose and matched the level of risk in each area.
While the Amazon team had an initial idea of what they required, they welcomed outside-the-box thinking, which resulted in more situation-appropriate safety controls, reduced maintenance, and optimised operational space. The result is a workplace that sets a new benchmark for safety innovation in Australia’s logistics sector.
If you’re planning a new facility or reviewing your current safety controls, check out our 5 Step Safety Design video, which takes you through our process from start to finish. Still got questions? Give us a call, we’re here to help!
