For more than 10 years, our Traffic Separator System has been used by contractors and councils across New Zealand for lane separation, temporary traffic management, cycle lane delineation, intersection safety improvements, and a range of other traffic guidance applications.
It’s a proven and effective system. But over time, one piece of feedback kept coming through: while the rubber separator bases performed well, the flexible posts could be improved for durability.
That feedback is what led to the development of the ULTRAFLEX Separator System.
ULTRAFLEX was designed as a premium durability upgrade for projects where repeated impacts, lower maintenance, and longer service life are a priority.
So what’s actually changed?
Why We Made the Upgrade
The original Traffic Separator System has always done its job well: creating clear lane separation and visual guidance in a compact, modular format.
But we were always curious about how it was actually performing on the ground. After listening to contractors, some issues became apparent: the main challenge wasn’t the system itself – it was the posts.
Over time, repeated vehicle impacts could cause the older rigid plastic posts to become brittle, crack, or eventually break. In some cases, the posts could also loosen in the socket after repeated hits, which meant more replacements and more maintenance.
The Three Biggest Improvements
The ULTRAFLEX Separator System keeps the same practical separator base design but introduces three key durability upgrades.
1. Flexible Polyurethane Posts
The biggest change is the post material itself.
The original Traffic Separator System used a more rigid plastic post. It worked well, but after repeated impacts it could splinter, shatter, or fatigue over time.
The ULTRAFLEX post is made from fully flexible polyurethane, designed to bend under impact and rebound back into shape.
So when a vehicle clips or drives over the post, it flexes instead of failing meaning less breakage, fewer replacements, and a cleaner site.
2. One-Piece Post Design
The original post used a two-piece construction, joined together with a connector screw. While that design worked, it naturally introduced another connection point that could loosen or fail over time.
The new ULTRAFLEX post is a single continuous piece that locks directly into the separator base. Fewer parts means fewer weak points and a much tougher system overall.
3. A Stronger Locking Socket
We also redesigned the connection socket.
The original Traffic Separator System used a twist-lock style connection. While effective, repeated impacts could sometimes cause the post to rotate, loosen, or eventually pop out.
The new ULTRAFLEX Separator System uses a deeper, more secure locking mechanism with a positive click-in connection.
This gives the post more support and helps it stay in place, even after repeated impacts. Similar to how an in-ground bollard behaves, if the post is knocked loose, it still remains captured within the base.
This feature alone reduces the risk of losing posts and removes the need for maintenance callouts.
How Much More Durable Is It?
The ULTRAFLEX post has been independently performance tested and certified to withstand 100 hits at 100km/h.
That’s a substantial jump in durability and gives contractors more confidence in high-use environments where repeated contact is expected.
Image: Old plastic post broken after 30 hits (left) while ULTRAFLEX post still looks brand new (right).
In practical terms, it means:
- Less time replacing broken posts
- Less maintenance across the life of the project
- Fewer site visits to check or reset separator lines
- Lower total cost over time
While the upfront investment is higher, the long-term maintenance savings pay for themselves over time.
Which System Is Right for Your Project?
The right choice really comes down to your application.
The Traffic Separator System remains a solid and cost-effective option for projects where budgets are tighter or impact frequency is lower.
The ULTRAFLEX Separator System is the better fit where durability matters most – especially in busy car parks, high-traffic lane separation, temporary traffic management, and permanent installations where ongoing maintenance can become costly.
While ULTRAFLEX provides a significant durability upgrade for high-impact zones, both systems still deliver the same core function: clear traffic delineation and physical separation.
Looking to Upgrade?
If you already have an existing Traffic Separator System installation, there may be upgrade options available depending on your current setup.
If you’re not sure which system is right for your project, or you want to know whether your current separators can be upgraded, get in touch with our team – we’re always happy to help!
