Ingal Civil Products and Leap Australia: Building Safer Roads Faster
Ingal Civil Products and Leap Australia: Building Safer Roads Faster
Since 1933, Ingal Civil Products has been designing and manufacturing road safety barrier systems. Today, our in-house engineering team is bringing new products to market faster than ever, thanks in part to a strong working relationship with Leap Australia.
In our latest video, created in collaboration with Leap Australia, members of our team share how this partnership has changed the way we develop and validate our products.
Why development has traditionally been slow
Verifying the performance of roadside safety barriers has long relied on full scale physical crash testing. Between prototype fabrication, vehicle costs and accredited laboratory fees, the overhead is significant. Refining a design through physical testing alone takes time and money.
A partnership that changed our workflow
Through our partnership with Leap Australia, we integrated advanced simulation into our development process. Our engineers use data from previous physical crash tests to build calibrated models, which lets us run rapid design iterations at a fraction of the cost.
Leap Australia has been with us every step of the way. Their ongoing technical support has been invaluable, and they act as a direct extension of our team.
The Ingal Long Span Barrier shows what this looks like in practice. Our team began with conceptual sketches and reached a final production design within three months, a timeline that would typically take years through traditional methods.
During those 90 days, we progressed through eleven design iterations, fine tuning material grade, geometry and vehicle interaction to optimise end user safety and product compliance.
Physical crash testing is still required for regulatory approval, and that does not change. What our approach gives us is the confidence we need before investing in a physical test. For the Long Span Barrier, our results met all MASH requirements, and the real world crash test aligned precisely with our models. The product is now fully accepted for use across Australia and New Zealand.
Designers and contractors regularly ask us about post spacing. A standard configuration works well on most roads, but different road conditions can create real challenges for installers and designers.
For Ezy-Guard 4, our engineers built a baseline model from existing crash test results and adjusted the design to replicate reduced post spacing. The analysis showed that reduced spacing improves safety performance while maintaining MASH compliance.
For our technical sales team, this means we can put real data in front of customers and give them the confidence to specify it for their projects.
Thank you, Leap Australia
This collaboration has expanded our engineering capabilities and significantly shortened our development cycles. Thank you to the team at Leap Australia for their support and for working so closely with us.
If you would like to understand more about Ingal Civil Products and our capabilities, we would love to hear from you.
Watch the full video here. https://youtu.be/2C7Xnw2v16Y