Automated Cone Trucks

Redefining Road Safety with Automated Cone Trucks

Australia’s First Commercially Available Automated Cone Truck

At KPI Construction Services, safety and innovation are not just slogans — they are embedded in everything we deliver. In 2023, KPI became the first traffic management company in Australia to introduce the Automated Cone Truck (ACT), a world-class engineering solution designed and built in Australia.

The ACT represents a step-change in how temporary traffic management is deployed. By removing workers from live lanes during cone setup and retrieval, we are not only setting new benchmarks for road safety but also redefining efficiency, sustainability, and inclusivity in the industry.

Why the ACT Matters

The Automated Cone Truck was designed with one purpose: to make dangerous work safe. Traffic controllers face daily risks from live traffic exposure, fatigue, and repetitive manual handling. The ACT eliminates these hazards by automating cone deployment and retrieval, ensuring that no worker is required to step into a live traffic lane.

Key benefits include:

• Zero Lane Exposure – Cones are deployed and retrieved from within the vehicle, protecting workers from oncoming traffic.
• Proven Safety – Following an extensive 18-month freeway trial, the ACT demonstrated significant improvements in safety outcomes across multiple high-speed projects.
• Operational Efficiency – Site setups and pack-downs are faster, reducing disruption for road users and lowering project costs.

Safety by the Numbers

The impact of the ACT can be measured in real, tangible outcomes:

• 85% reduction in worker exposure to live traffic lanes.
• 2 units currently deployed across KPI’s fleet and available for client projects.
• KPI is carbon-neutral certified.
• 18-month trial completed on Victorian freeways, validating the ACT’s performance in real-world conditions.

These results are not future promises — they are proven, measurable outcomes already transforming the way road safety is managed in Australia.

Manual vs Automated Deployment

Traditional Manual Deployment:

• Workers step into live traffic environments.
• Deployment and retrieval are time-intensive.
• Risk of fatigue, musculoskeletal injuries, and near misses.
• Higher labour requirements and increased exposure to compliance risks.

Automated Cone Truck Deployment:

• Workers remain inside the vehicle at all times.
• Cones are deployed and collected automatically with precision.
• Reduced fatigue, improved wellbeing, and higher workforce retention.
• Optimised resourcing, lower labour intensity, and improved project efficiency.

The Human Story

Beyond statistics and trials, the ACT has a human story. In 2023, Leasa Condon became Australia’s first Automated Cone Truck operator, setting a new milestone in the industry. Her journey demonstrates KPI’s values of inclusion, adaptability, and continuous growth.

By introducing new roles and redefining traditional site operations, the ACT has opened pathways for operators from diverse backgrounds — including women, return-to-work parents, and those who may not have previously considered traffic control as a safe or sustainable career.

Innovation Timeline

• 2023: KPI launches Australia’s first Automated Cone Truck.
• 2024: Successful completion of an 18-month freeway safety trial.
• 2025: KPI expands its national fleet with a second Automated Cone Truck.
• Future: Ongoing innovation and R&D in partnership with our suppliers, ensuring continuous improvement in road safety and sustainability.

KPI has a strong history of industry firsts — from automated cone trucks to solar-powered traffic devices and on-vehicle innovation. The ACT builds on this legacy, reinforcing KPI’s position as Australia’s most forward-thinking traffic management provider.

Leadership Perspective

“Every worker deserves to go home safely. The Automated Cone Truck ensures that safety is not a goal — it’s the standard. This investment is not just about technology; it’s about changing the way our industry operates for good.” – KPI DirectorBring Automation to Your Next Project

The Automated Cone Truck is available now across KPI projects in Australia. Clients can access this innovation as part of our broader traffic management solutions, ensuring safer, faster, and more sustainable outcomes on high-speed roads, freeways, and complex civil projects.

Contact our team to discuss how the ACT can be deployed on your next project.