Case Studies
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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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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A Recipe for Safety at Mauri Flour Mill
Flour might seem light, fluffy, and admittedly a little bit messy, but when you go from the kitchen to transporting it around in bulk, it’s heavy, dusty, and combustible stuff. With stock moving around constantly at this busy flour mill, there are plenty of health and safety hazards. On-site personnel, visiting delivery drivers, forklifts carrying bulk pallets, obscured views, and noise make it a recipe for disaster, if you will. Our solution? Adding a few heaped servings of our Tru-Gard Barrier into the mix. With different configurations for different zones, we wanted to ensure we had the right safety solution for each area. From 910-2 for vehicle-only zones, to 910-2 + Hand Rail for pedestrian areas, and a super solid 910-3E with Personnel Gates for customised Driver Protection Zones. A lot of customers have been looking into driver protection options for their sites lately. From custom configurations like this one to our new Driver Protection Zone Kits, each option is designed to ensure visiting drivers have somewhere safe and secure to be while their trucks are loaded, and no one on site is unsure where they should be waiting or where the designated safety areas are. We know drivers like to make the most of a stop, getting out to stretch their legs, get some fresh air, and take a break, but making sure they can do so safely is a high priority for us. We’ve designed different configurations to suit different sites and can offer everything from a simple handrail area to a fully enclosed mesh cube, depending on the hazards on your site. After all, it takes a team to keep everyone safe. So, to wrap up, we took a couple of scoops of barriers, a pinch of accessories, and a dash of safety know-how and voilà, a piece of cake safety solution that works. If you think your on site health and safety recipe could do with a few more ingredients, get in touch with our team today to find out more.
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Stocked Up on Safety at Foodstuffs Dunedin
This very large and busy distribution centre, right here in our backyard (Dunedin, NZ), handles high volumes of dry grocery products every single day. Keeping supermarket shelves stocked is no small task, which means forklifts are constantly moving goods in and out, with ground personnel working in close quarters. Several workstations are located in these high-traffic zones, so the risk of injury from a forklift is a serious health and safety concern. Working alongside our team, Foodstuffs developed barrier zones around these workstations and in high foot-traffic areas to make the workplace safer for staff. Using our 910-2 system, these barriers can withstand impacts from forklifts if needed while providing a clear visual guide for drivers on where pedestrian zones are. Here’s what the team at Foodstuffs had to say about the product and install process: “Impressed with the end product and workmanship. Also impressed with the professionalism while you were on site, i.e. health and safety, documentation, speed of delivery, attitude, knowledge, and general engagement with the team.”— Matthew Peoples, Health & Safety Manager, Foodstuffs South Island If you’ve got a high-traffic, high-hazard environment, contact our team today to find out more about the Tru-Gard products best suited to your unique site and hazards.
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Counting on Safety at Woolworths Christchurch Distribution Hub
If you need reliable protection for your assets, you can count on us, and that's exactly what Woolworths did for their Christchurch Distribution Hub. The Christchurch Regional Distribution Centre was built from the existing Woolworths Distribution Centre, which was significantly affected by the September 2010 earthquake. The complex includes a 22,000 sqm warehouse and a 7,000 sqm receiving and dispatch canopy. Following a $20 million construction and fit-out programme completed in June 2012, the dispatch canopy was added, and site managers requested Tru-Gard protection to safeguard the structure. Protecting High-Traffic AreasSupplying approximately 7,800 product lines to more than 68 Woolworths, SuperValue, and FreshChoice stores across the South Island, the centre sees a constant flow of heavy trucks and working vehicles. With so much activity, the risk of accidental collisions with the dispatch canopy is high. Our solution was Tru-Gard Certified Safety Barrier configuration 610-2. This system features 610 mm-high support posts secured to the concrete base with heavy-duty screw bolts and two barrier rails spanning the full run. Proven Protection Over TimeFor several years now, this barrier system has provided first-class protection, guarding against everything from minor grazes to more significant knocks, ensuring both the structure and site operations remain safe. Solutions Supplied Tru-Gard™ Certified Safety Barrier 610-2
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Heavy-Duty Safety for Mondiale’s Auckland Hub
A big name in international freight, Mondiale VGL are experts in all things freight and logistics. Operating across some of the world’s most significant trade routes, by air and sea, their operations involve a constant flow of import and export moving parts. From container movements to pallet transfers and heavy-duty haulage, there are plenty of opportunities for health and safety risks. So, when they needed to add extra safety to their Auckland HQ, they knew who to call. Their Auckland office, situated near the country’s largest airport, is a constant hive of activity. The Mondiale team approached us to enhance health and safety around their warehouse. With busy walkways, exposed workstations, driver delivery zones, parcel conveyors, and a steady flow of traffic, they needed a robust solution to protect their people and maintain efficient operations. We supplied a full suite of Tru-Gard safety solutions, including barriers, handrails, and personnel gates—all designed to keep pedestrians separated from forklifts and out of freight zones. We also used this project as a chance to install our new flat end cap: a sleek, compact alternative to the standard barrier end, offering a neat and streamlined finish to each barrier run. In total, the site was equipped with a massive 453 metres of barrier. The Tru-Gard™ 910-2: Built for High-Impact Zones At the heart of this installation is our most popular configuration—the 910-2 Safety Barrier. It provides strong, visible protection, is built to take the impact, and, finished in our signature safety yellow- it stands out on any site. Let’s Make Your Workplace SaferIf you’re looking to improve safety around your logistics or distribution facility, our team can help. From high-volume freight zones to pedestrian protection, we’ve got solutions that work.
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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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