Case Studies
Driving Safer Solutions for Port of Auckland
When New Zealand’s largest import port is building a five-storey car park, it requires a bespoke barrier solution. That’s where our custom manufacturing abilities, decades of experience, and commitment to safety come together to create one of our largest projects to date. The Tru-Gard Solution: Port management requested a custom-designed version of our standard Tru-Gard Barrier system, with 1100mmH support posts coated with a special XR coating system and finished in ‘safety yellow’ to match the rails. Every post is secured to the concrete with a 5-bolt footprint for maximum strength and stability. The top hand rail was specially designed with a square profile for easy attachment directly onto the support posts. Similarly, a lower guardrail of the same profile was added underneath the main barrier to ensure full safety for pedestrians, preventing accidental slipping through the gap and falling out of the building. This carpark building is located centrally in Auckland where both the main port and the city’s CBD come together within highly-populated proximity. Great effort has been put into making the building as attractive as possible in its setting, including a wonderful light show by night. It is an architectural sight to behold while also being one of the safest multi-story buildings in the city. __ __
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More than just bad parking: A Tru-Gard Safety Insight into Safer Car Parks.
Car parks – they’re everywhere, and they’re full of hazards. No, we don’t just mean people’s questionable parking; there are genuine dangers, including moving traffic, rogue trolleys, and pedestrians to watch out for. Incidentally, we have a simple, non-moving solution for making these areas safer – our Tru-Gard Bollards. Available in safety yellow or galvanised finishes, they can be installed in your choice of removable, surface-mount, or in-ground configurations to suit. While this may sound vaguely like the safety equivalent of a fast-food order, side note also perfect for these sites, our bollards are the ideal solution for sites where pedestrians and vehicles need to be separated. The benefits don’t end there – our Tru-Gard bollards are perfect for supermarkets, shopping centres, sports grounds, hospitals and healthcare centres, stadiums, or anywhere pedestrian and vehicle traffic need to be kept apart. They are also backed by our 10-year warranty and have been independently tested to ensure they are up to the task. By minimising risks and ensuring clear boundaries, our bollards help make these spaces safer for everyone – reducing accidents and providing peace of mind for both drivers and pedestrians. “At Tru-Gard, we’re driven by a commitment to make every car park safer – from quick supermarket stops to hospital visits. Our bollards provide a reliable way to keep people and traffic safely apart. Wherever your park, we’re working to make it safer.” – Bromley Taylor, Safety Sales NZ If your site could do with additional safety or, you’d like our team to provide advice for your space contact us today to find out more about our customised safety solutions.
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Bollards, Barriers, and Beyond at Bunnings Timaru
If you’ve ever shopped at a Bunnings Warehouse, especially on a sunny day or public holiday, you’ll know just how busy the place can be. With customer vehicles constantly on the move, trucks making deliveries out the back, forklifts shifting stock, and plenty of pedestrians and staff on foot, it’s a hive of activity. With all these moving parts, it was essential to develop a safety solution that considered every aspect. We worked closely with the team to identify risks and hazards specific to their store and create custom safety solutions to suit. The Tru-Gard Solution: At the front, Tru-Gard Bollards keep pedestrians safe and the building protected from any accidental “put it in drive instead of reverse” incidents. Out the back, Tru-Gard Barriers safeguard team members and the building from damage caused by wide-swinging trucks and forklifts laden with heavy pallets of hardware. We also supplied Tru-Gard Expanding Barriers, enabling staff to create temporary safe zones while they work and redirect pedestrians around short-term hazards. The Products: Tru-Gard Certified Safety Bollards Tru-Gard Certified Safety Barrier Tru-Gard Expanding Barrier By working together, this store is now safer for staff, shoppers, and store assets. If you’d like to know more about customising a safer space for your site, contact our team today.
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From Sketch to Safety Solution: Reinventing Safety at Winstone Wallboards
We recently had the privilege of designing and manufacturing a cutting-edge safety walkway system that has set a new standard for pedestrian protection in busy warehouse environments. This game-changing solution has transformed Winstone Wallboards state-of-the-art facility in Tauranga, New Zealand, into a highly secure zone for foot traffic, significantly enhancing safety in high-risk areas. From the outset of this new-build project, our Research and Development (R&D) team was partnered with Fletcher Building to bring their vision to life. Taking into account the risk, we customised a safety walkway system tailored to the unique demands of the site. Drawing on decades of experience and innovation we created an outcome to suit the strict safety and operational requirements. Key Features:The final product represents a seamless integration of innovation and functionality, delivering outstanding safety outcomes, including: – Encased Protection: Fully enclosed on all sides, safeguarding pedestrians from hazards such as falling objects and vehicle impact. – Space-Efficient Design: Modular installation with a minimal footprint preserves valuable storage and operational space. – Structural Integrity: Long, straight tunnels engineered for exceptional strength, durability, and impact resistance. – Code Compliance: Fully tested to meet and exceed regulatory standards. – High Visibility: Finished in a vibrant, safety-yellow coating for maximum visibility and awareness. – Personnel Gates: Strategically placed for convenient and safe pedestrian access and egress. “Tru-Bilt Industries exceeded Winstone Wallboards expectations by engineering and delivering a solution that surpassed everyday safety measures. Their ability to innovate and adapt to the unique layout and risks of the warehouse ensured that all safety concerns were comprehensively addressed. They engineered the optimal solution to meet our needs”– Stewart Vaughan, Project Lead – Tauriko Development, Winstone Wallboards Ltd This bespoke safety solution has not only enhanced the operational safety of Winstone Wallboards warehouse but also demonstrated the power of close collaboration between manufacturers and clients. By addressing site-specific challenges and delivering a system that exceeds safety standards, we’ve created a protective environment that supports productivity without compromise. Read more about the product here. Our thanks to Stewart and the team from Fletcher Building for trusting us to create a solution that makes their workplace a safer place to be.
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Preventing Fatalities & Injuries for Ports, Cold Stores, & Shipyards: A Tru-Gard Safety Insight.
In the busy, high-risk environments of ports, cold storage facilities, and shipyards, protecting people, products, and property is paramount. These dynamic workplaces come with inherent risks, from separating pedestrians and traffic to managing freight and safeguarding high-value assets. From unloading freight into cold storage to navigating bustling packing and handling facilities, hazards are everywhere. Customised Safety Solutions for Every Space Tru-Gard products are designed to meet the unique needs of each facility. From internal fit-outs to external safety, our solutions are configurable to suit any layout or hazard profile. Whether you need to separate pedestrian walkways from vehicle paths, protect racks of stock from forklift damage, create safer work zones for staff, or safeguard doors against truck damage, Tru-Gard products ensure every corner of your workplace is covered. Our Product Range: Built for Protecting Our versatile product range includes: Handrails and barriers: Essential for creating safe walkways for pedestrians, separating vehicles, and protecting property from damage. Door frame bollards: Protect entry points and commercial doors from impact damage. Cast-in and removable bollards: Offering flexible solutions for permanent or temporary installations. Mesh tunnels: Safeguard workers in high-risk zones while preventing damage from falling stock. Pallet protection: Safeguard pallet racks and stock. Personnel gates: Provide controlled access points for pedestrians. Every product is designed and manufactured in Dunedin, New Zealand, ensuring the quality and durability needed to withstand the harsh demands of these environments. Between 2012 and 2023, 18 deaths were reported among port workers in New Zealand, with an average of 1.8 fatalities per year.**Source NZ Herald, 20 Oct. 2023 Proven Expertise Across New Zealand & Australia Our team has worked on projects across the country, from the northernmost ports to the southern tip of New Zealand. Our experience spans diverse facilities, including temperature-sensitive cold stores, cruise ship passenger terminals, car parking, and busy docks. This breadth of expertise enables us to understand the specific challenges faced by New Zealand and Australian ports and deliver tailored solutions that work. Why Choose Tru-Gard? Risk reduction: Minimise the chances of damage to products and property, and most importantly, reduce the risk of accidents or loss of life. Operational efficiency: Streamline workflows by meeting safety requirements, reducing downtime from accidents, and avoiding costly repairs. Durable solutions: Products built to last in demanding environments, with finishes suitable for internal and external applications. Locally owned and operated: Proudly NZ-made, supporting local businesses that understand the unique challenges of the New Zealand and Australian environments. Real-World Impact: Safer Workplaces, Stronger Operations As published in the New Zealand Herald, between 2012 and 2023, 18 deaths were reported among port workers in New Zealand, with an average of 1.8 fatalities per year. With a stevedore fatality rate of 20 deaths per 100,000 workers, the second-highest fatality rate of any sector in New Zealand. Although no safety product can prevent every accident, Tru-Gard has a proven track record of helping businesses improve operations and mitigate risk. For instance: At Port Otago, our custom handrail and bollard system reduced risks by keeping cruise ship pedestrians separated from moving vehicles, preventing tourists from entering high-risk areas. In other ports, our solutions have minimised near-misses and accidents between forklifts and pedestrians in busy freight zones. At the San Won cold storage facility in Timaru, our barriers and personnel gates have provided clearly defined, safer pedestrian walkways, and ongoing protection against damage, saving the business time and repair costs. Let’s Make Your Workplace Safer If you’re looking to enhance safety in your port, cold store, packing facilities, or shipyard, Tru-Gard is here to help. Whether it’s a new-build project or assessing your current safety measures, contact our team today to learn how we can make your workplace safer. Read another Tru-Gard Safety Success Story Here
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Heavy Haulage Meets High Safety at Mainfreight Hobsonville
We’re excited to introduce Mainfreight’s brand-new distribution centre on Westpoint Drive, Hobsonville. This state-of-the-art facility allows Mainfreight to service its customers in western and northern Auckland from a strategically located base, reducing reliance on facilities over an hour away. From this new location, Mainfreight supports freight operations across a vast region, stretching north from the Auckland Harbour Bridge to Te Hana and west from Henderson to cover all of West Auckland. This area represents a significant portion of Auckland’s freight traffic—approximately 35-40% of the city’s total volume. To accommodate this, the depot has been built on a grand scale, with a massive 15,000 m² footprint that includes the main depot floor, loading zones, and extensive truckways and breezeways. The facility also features three raised dock levellers, a commercial-grade gantry truck wash, and parking for 100 vehicles, ensuring the site is equipped to handle the high volume of activity it sees daily. To protect key areas of this high-traffic site, Mainfreight partnered with us to install robust steel solutions. The project included our Tru-Gard™ Downpipe Protectors, large Cast-in Bollards, and several runs of Certified Safety Barrier, all designed to safeguard vulnerable parts of the building from heavy transport and lighter vehicle movements. Our signature, high-visibility, galvanised yellow was chosen to withstand outdoor weather conditions while ensuring safety—plus, it perfectly complements Mainfreight’s bold corporate colours. The result? A bright, functional, and resilient depot ready to meet Auckland’s freight demands. Tru-Gard Products Used on this Project: Bollards Safety Barrier Downpipe Protectors Wheel Guides
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Trailblazing Safety Solutions for Mountain Biking Otago
Here at Tru-Gard, we love the opportunity to provide a safety solution for more unusual spaces. So, when the team from Mountain Biking Otago got in touch about their car park, we were excited to offer a tailored solution that would meet their unique needs. Much like carrying a puncture kit or wearing a helmet, having visible, strong barriers in your car park just makes sense. Whether you’re managing an outdoor adventure site or any location where vehicles and people need to stay separated, the right bollard solution can make a significant difference. At Mountain Biking Otago, large SUVs and utes are commonly used to transport bikes, but with multiple riders and vehicles on site, safety and organisation are crucial. Tru-Gard Certified Bollards keeping adrenaline seekers and vehicles separated. “At Tru-Gard, we thrive on tackling unique projects, so collaborating with Mountain Biking Otago on their car park was a fantastic opportunity for us. Creating a safe, well-organised space is essential in any high-activity site like this, where large vehicles and multiple riders need clear boundaries. Our removable bollard solution not only brings the flexibility needed for their dynamic environment but also adds an extra layer of safety to help keep riders and vehicles in their own lanes.”– Bromley Taylor, Safety Solution Sales NZ By installing removable bollards, we gave Mountain Biking Otago the flexibility to clearly define their car park and separate vehicle zones from pedestrian areas. The bollards help keep vehicles out of spaces where they’re not needed, reducing the risk of accidents, and ensuring that areas are used for their intended purpose. This simple yet effective solution also allows for easy adjustments — bollards can be added or removed as required, making it easy to accommodate changes in traffic, site use, emergency access or any other changes as needed. These bollards are not only practical; they’re also highly visible, clearly marking where drivers and riders should and shouldn’t be. In a busy, action-packed environment like a mountain biking site, visibility and safety are paramount — and our Tru-Gard bollards help enhance safety for everyone on site. If you’d like to learn more about bollard solutions for your site, whether standard or tricky, contact our expert team today, or view our range here. NZ Sales – Bromley Taylor, bromley.taylor@tru-gard.com __ Read another Tru-Gard Safety Success Story Here Tru-Gard Certified Bollards creating clearly defined zones for riders and drivers. Please note bollards featured in this project use a former cap design.
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Protecting Port Otago Pedestrians
Take one busy port terminal, combine it with thousands of port staff, seafaring workers, cruise ship passengers, and other visitors, and you have a recipe for a high-risk area. Port Otago’s shipyard is a constant hive of activity, with traffic flowing throughout the day, heavy machinery moving shipping containers, and plenty of people on foot. The risks to both people and property are significant. Clearly defined walkways can mean the difference between safely navigating the area and a serious incident. The Tru-Gard Solution: We partnered with the Port Otago management team to design and install a Tru-Gard Hand Rail system in their high-traffic pedestrian zones, including the port entranceway, office areas, and cruise ship terminal. Before the project, pedestrians struggled to identify safe pathways. Now, clearly marked spaces ensure that those on foot can navigate the area safely and confidently. It was essential for us to address the specific risks identified by Port Otago—whether for their staff or international visitors. The solution needed to provide unmistakable guidance for pedestrians, while also ensuring a clear separation from moving vehicles. Our Tru-Gard Hand Rail system met these requirements, creating a safer environment for everyone using the space. Designed for New Zealand’s unique conditions, our multi-purpose, heavy-duty system is built to withstand the wild, windy, salt-laden weather that can batter southern ports. The Tru-Gard Hand Rail is highly configurable, making it an ideal safety solution for diverse settings—from busy shipyards to sports grounds, factories to freight operations, and everything in between. If you’d like to learn more about how our products can make your workplace safer, contact us today.
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Turning Port Otago’s Carpark into a Safety Stronghold
When Port Otago needed additional protection for both pedestrians and vehicles in their new carpark, they knew just who to call. As part of a significant upgrade to surrounding land and infrastructure, including the construction of a newly built company carpark, Port Otago sought safety solutions for a variety of applications. The carpark, which spans different levels and is adjacent to a busy road with a high volume of heavy transport traffic, posed unique safety challenges. The existing combination of concrete walls and steel fencing simply didn’t feel secure enough. Working closely with Port Otago’s management team, we designed a tailored safety system that incorporated Tru-Gard bollards, hand rails, and barriers, providing an extra layer of safety for both pedestrians and vehicles. These solutions were strategically positioned to protect vulnerable areas and direct traffic safely, enhancing the overall safety of the site. Bromley Taylor, Safety Solutions Expert at Tru-Gard, commented on the importance of safety in environments like Port Otago:“Safety is something we take seriously from the moment an employee steps onto a site. In high-traffic, multi-level environments, like this carpark, it’s essential to put the right safety measures in place from the very beginning—before employees even start their day. By working together with Port Otago, we were able to create a comprehensive safety system that significantly reduces the risk of accidents, ensuring that everyone on-site is protected.” This collaborative approach allowed Port Otago to ensure their carpark met the highest safety standards, providing peace of mind to both staff and visitors. Find out more about how our bollards, hand-rails and barriers can create a safer working environment for your team. Contact us today.
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