Case Studies
Delivering Safety at Scale for NZ Post’s New Super Depot
In high-volume logistics and parcel processing centres, we know safety is just as critical as speed. With large teams working alongside fast-moving machinery, vehicles, and thousands of parcels, every metre of the facility must be designed with protection in mind. So, when NZ Post set out to build their new ‘super depot’ in Grenada, Wellington, they knew our products would be up for the challenge. Spanning over 10,000m², this new depot is equipped with some of the world’s most advanced parcel sorting and scanning technology. But with hundreds of people on site every day, continuous traffic movement, and freight in constant flow, protecting people, infrastructure, and of course, precious cargo, was a top priority. That’s where we came in. Our team supplied a range of Certified Safety Barriers and Bollards throughout the facility. And while there’s plenty of iconic NZ Post red, our signature safety yellow still stands out—and for good reason. It was essential that our products be clearly visible across the site. Our solutions help ensure safer pedestrian movement, protect vital infrastructure, and reduce the risk of accidents across key operational zones, without interrupting your parcel deliveries. This wasn’t just an investment in infrastructure and technology for NZ Post—it was a proven investment in team safety. For this project, we supplied: Safety barriers: To define walkways, and protect equipment. Bollards: To equipment, and structural assets from vehicle impact. Let’s Make Your Workplace SaferIf you're building or upgrading a distribution centre or logistics facility, talk to us about integrating smart safety solutions into your project. We can assess your site and recommend the optimal safety system to make your workplace safer. __ Photo credit: Robert Keenan, NZ Post
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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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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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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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Transforming Pedestrian Safety at Mainfreight Derrimut
What do you do to ensure uninterrupted deliveries for your customers while also completing a safety upgrade at your depot? You call the team here at Tru-Gard. Keeping a busy 3PL depot running smoothly while updating the safety system is no small feat, but when the team from Mainfreight Derrimut contacted us to upgrade their barrier system, we were confident we were up for the task. Working alongside National Operations Support, Shane and Derrimut Branch Manager, Nathan, our team created and quoted a custom safety solution, coordinated the installation, and even arranged environmentally friendly disposal of the old system. The Tru-Gard Solution: Working closely with the team, we recommended our 610-1-1100 Barrier System and a combination of Personnel Gates, designed to keep people and forklifts apart, keep pedestrians away from active roller doors, and generally make the area a safer place to work. After the initial system design, our team and the approved installer conducted a site visit for final tweaks. This visit offered the chance to understand the daily workings of the depot and make essential alterations, including additional gaps in the barrier system to allow for higher traffic flow areas. The Tru-Gard Products: Barrier – 610-1-1100 Flat End Caps Personnel Gates Tru-Gard Certified Barriers keeping pedestrians, freight, and forklifts separate. The Process: To ensure the depot could continue to run smoothly, we conducted the installation in phases, working on different areas to suit and avoiding any major disruptions to day-to-day operations. During the installation process, we also removed the existing damaged handrail and old gates, using a Sims Metal skip on site to ensure the steel was recycled wherever possible. “We are thrilled to have provided a safe solution for the team at Mainfreight in Derrimut. Our longstanding relationship with Mainfreight makes this project particularly meaningful for us. Ensuring the safety of their team aligns with our core values, and we are proud to contribute to their ongoing commitment to a safer working environment” – Mark Taylor, Managing Director Tru-Gard Before & After – The old gates and barriers and the new Tru-Gard Certified Solution. We have used Mainfreight to transport our products for decades, so our team was thrilled to work on this project, helping keep the team who keep our products moving safe from harm. If your branch’s safety systems need an upgrade, or you are looking for a new, fully customised safety solution, contact our team today to find out more. Our thanks to Nathan and Aleks, from the Derrimut Branch, and Shane from Mainfreight Australia, for choosing Tru-Gard. __ __ __
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