Case Studies
Barrier Up & Risks Down at this Auckland Warehouse
One of our most popular barrier setups is the 910-2 Barrier, and for the cherry on top it's finished with our Tru-Gard Hand Rail. This was the solution of choice for a large new-build warehouse in Auckland, where the goal was simple: keep pedestrians safe while they navigate the full perimeter of the building. Personnel Gates were placed in key high-traffic areas, including office entrances and exits. By slowing people down and requiring them to open the gate before stepping onto the warehouse floor, staff get a moment to check for forklifts and moving vehicles. It’s a small pause that makes a big difference when people and machines share the same space. Bollards were also installed in strategic locations to protect sensitive electronic equipment. Nobody wants downtime caused by accidental damage, and our certified bollards provide tough, reliable protection exactly where it’s needed. This project is a solid example of how we combine smart design, certified protection, and practical placement to keep both people and assets safe. In a busy warehouse, it’s these little touches that make a big difference. \\
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Where Foot Traffic Safety Meets Freight at Mainfreight Dunedin
If you’ve had a look through our case studies, you will see we’ve worked with our fair share of Mainfreight depots over the years. So we have learned a thing or two about the hazards and requirements of their busy transport sites. People are at the centre of everything Mainfreight do, and keeping pedestrians safe on site is always a priority. It’s something we’ve enjoyed collaborating with them on many times before. Creating safe walkways in high-traffic zones is something we do best. So when the Dunedin branch needed help, we were happy to advise. This busy depot sees national consignments move in and out all day, every day. Our role was to help establish a secure pedestrian zone around the warehouse, separating foot traffic from forklifts. A combination of our Barrier, Hand Rail, and Personnel Gates was the ideal solution, providing modular, high-visibility products that fit seamlessly into the environment. Built to last with a 10-year warranty, staff and visitors can have the confidence that this is an investment in their safety for years to come. This site is just another example of how we partner with Mainfreight to put people protection first, every step of the way. Read more about our work with Mainfreight Hobsonville, Mainfreight Derrimut, and Mainfreight Gore.
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Saving Downpipes & Dollars at Mainfreight Gore
Smashed downpipes cost businesses thousands of dollars every year, yet they’re often some of the most exposed and overlooked parts of a building. Time and time again we see it happen: a vehicle gets too close to a wall and side-swipes a downpipe, leaving fragile material broken and unusable. If you’ve ever had to replace one, you’ll know how painful it is, both in terms of extra work and unexpected costs. One of the handiest steel products we make is our Tru-Gard Downpipe Protectors. You can go subtle with a galvanised steel finish, like these installed at a Mainfreight Gore, or stand out in our classic ’Safety Yellow’- the choice is yours. This project was a new-build depot for Mainfreight, a busy transport site with trucks and forklifts moving around constantly. Several downpipes needed extra protection, and these weren’t just any downpipes. They carry water under pressure from a large collection tank on the roof, so any damage could have caused serious mess and disruption. The standard galvanised finish not only protects against the elements but also blends seamlessly with the building’s corporate colours. The result is a smart-looking, well-protected building that keeps both downpipes and operations safe. If your assets could do with an added layer of protection you can shop our downpipe range here or contact our team today for more information.
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Keeping People and Freight Moving Safely at Lindsay Transport
Lindsay Transport is one of Australia’s largest transport companies, moving more than 1.6 million tonnes of freight for over 5,000 customers along Australia’s east coast each year. With more than 37 stores and depots, health and safety is a core consideration across its warehouse and logistics operations. At this Victorian freight site, the day-to-day environment is busy and complex. High volumes of pedestrian workers move throughout the warehouse and around loading and unloading bays, while a constant flow of trucks and forklifts keeps the site active from start to finish. The focus of this Tru-Gard project was clear: create well-defined, safe pedestrian walkways for staff and visitors navigating the site. Working alongside our local supplier and installer in Victoria, we installed long runs of 910-2 Tru-Gard Barrier and an added handrail. Multiple Personnel Gates were also added to control foot traffic and prevent pedestrians from stepping directly into high-risk driveways and forklift zones. The result is a site with clearer separation between people and vehicles, improved traffic control, and safer movement throughout the facility. It is a practical example of how thoughtful barrier placement and pedestrian management can reduce risk in busy freight environments, without compromising day-to-day operations. If your site could do with a safety overhaul, chat to our team about everything from Barrier to Driver Protection Zones and a modular safety system to suit.
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Built to Take the Hit: The Story of Tru-Gard Downpipe Protectors
Back in 2019, we started seeing a clear trend across factories and warehouses. Sites were busier, vehicles were bigger, and the knock-on cost of damaged building services was becoming harder to ignore. Downpipes in particular were taking a hiding in high-traffic areas. That growing demand for better asset protection led to the launch of our Downpipe Protector range. This Christchurch warehouse project was one of the first to put them to work, with 17 Downpipe Protectors installed as part of the site fit-out. From the outset, the focus was simple. Protect vulnerable services, reduce repair costs, and help drivers spot hazards before contact ever became an issue. Typically, Downpipe Protectors are installed from ground level to shield the most exposed section of pipework. On this site, however, some downpipes were positioned in areas used by larger trucks. To suit the traffic profile, several protectors were installed slightly above ground level to guard against higher impact points, showing the flexibility of the system to suit real-world conditions. Finished in high-visibility safety yellow, the protectors act as an early visual warning for drivers moving through the yard. In most cases, that visibility alone is enough to prevent contact. If a minor collision does occur, the 3 mm steel guard absorbs the impact, keeping fragile pipework intact and maintenance crews out of reactive repair mode. Our Downpipe Protectors are available in standard and large sizes, with adjustable widths to suit a range of pipe diameters. Each kit is designed for straightforward installation and supplied with fixings and clear instructions, making them easy to integrate into new builds or retrofits. What started as a response to a growing problem has since become a core part of our asset protection range. Today, Downpipe Protectors sit alongside our Column Protectors and Pallet Racking Protectors, helping sites across New Zealand and Australia protect critical infrastructure and keep operations running smoothly.
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Safer Steps at CHEP Dunedin
It will come as no surprise that a busy CHEP warehouse is home to plenty of forklifts. It is also no surprise that these can create hazards for pedestrians, and that is where we come in. Creating safer foot traffic areas along the allocated walkways to and from the dispatch office and other areas of the store was a simple yet effective way to keep workers and site visitors safer. Once again, our 910-2 Barrier System, combined with Hand Rail, came to the rescue. High visibility, built for impact, and cost effective, it was the optimal solution. If you have walkways that could benefit from a touch of Safety Yellow barrier, talk to our team today to find out more.
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Walk this Way: Keeping Workers Safe at CHEP Auckland
Anyone who’s spent time in a CHEP warehouse knows they are busy places. Forklifts are constantly on the move, pallets are shifting, and staff are often navigating the floor on foot alongside machinery. It works well when everything runs smoothly, but clear separation is key to keeping people safe. That is where this project came in. To better protect staff on foot, we installed clearly defined pedestrian zones, surrounded by certified Tru-Gard safety barrier. These walkways give people a safe space to move through the warehouse, without having to second-guess what is happening around them. The solution uses our classic 910-2 Barrier System, designed to deliver strength, visibility, and peace of mind in busy warehouse environments. Personnel gates were added to provide practical access points between the pedestrian zones and the main warehouse floor, making it easy for staff to get where they need to go without crossing active traffic routes. In high-foot-traffic areas, a double-gate system was installed. One gate can be used for entering, the other for exiting, which helps keep foot traffic flowing and avoids those awkward bottlenecks during busy shifts. The end result is a safer, more organised warehouse environment where people and machinery can do what they need to do, without getting in each other’s way. All the right traffic management and health and safety boxes, ticked.
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Protecting Pedestrians at Pink Batts Penrose
Auckland - famously busy for both traffic and pedestrians, and this commercial area in Penrose, home to Pink Batts, is no different. Not only are staff and commercial visitors at risk in this busy industrial zone, it also provides everyday access for members of the public and the customers of neighbouring businesses. With so much traffic also using the area it was important to provide as much protection as possible to avoid dangerous accidents. By making full use of our modular Barrier and Personnel Gates, there can be no doubting the allocated pedestrian safety zone here. Tested and certified, there’s no doubt that visibility and durability are where it counts - creating a truly safe pathway for people. If traffic management is problematic at your site, have a chat to our team today about creating a custom, modular system that works for you and your hazards.
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A Heaping of Safety at Chelsea Sugar
Is there really anything sweeter than knowing your staff and assets are well protected and risks minimised? Well, if anything could be, it’s all of this combined with being on site at Chelsea Sugar (NZ Sugar Company) in Auckland, NZ. Wanting to take great care of their staff, they came to us for a solution that would stick. We suggested our certified and tested Barrier System, in a variety of configurations to suit height hazards and offering pedestrians protection against trucks and forklifts on site. Combined with our Personnel Gates, this provides safe access to the main floor so no one wanders in front of moving traffic. It’s a carefully crafted recipe for safety: a heaping of robust barriers, a dash of high-visibility yellow for maximum awareness, and a generous sprinkling of secure access points to keep staff and assets protected.
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