Case Study: Pinnacle Hardware Warehouse

A Complete Pedestrian Safety Upgrade

Project Overview

Pinnacle Hardware operates a high-volume warehouse that supports its extensive national supply chain. Within the facility, a pedestrian walkway ran directly through a busy pick-and-pack area, creating ongoing safety challenges as foot traffic intersected with forklifts and vehicle routes.

To address these issues, Pinnacle engaged Verge Safety Barriers to redesign the internal traffic flow and implement a fully segregated system that would enhance safety, improve operational efficiency, and maintain visual consistency throughout the site.

The Challenge

Pedestrians and forklifts were sharing the same zones, leading to a high potential for near misses and workplace accidents. The existing layout provided no physical separation between people and vehicles, causing congestion and workflow interruptions during busy periods.

Pinnacle required a safety solution that would:

1. Deliver complete separation between pedestrians and forklifts.
2. Integrate quickly without major disruption to operations.
3. Maintain a professional, brand-aligned appearance.
4. Offer long-term durability and minimal maintenance requirements.

The Solution

Verge Safety Barriers carried out a detailed site audit and developed a tailored traffic management strategy to ensure complete segregation between pedestrians and vehicles while maintaining warehouse efficiency and a cohesive visual standard.

To achieve this, Verge supplied and installed:

• Verge HD Barrier approx. 120LM
  Designed for areas with heavy forklift activity, the Verge HD Barrier delivers exceptional impact resistance and durability. It provides a robust physical divide between pedestrians and moving vehicles, significantly reducing collision risks in high-traffic zones.
•  Verge Eco-Rail approx. 100LM
  The Verge Eco-Rail is a lightweight yet strong pedestrian guidance system, ideal for defining walkways and low-impact areas. It combines excellent visibility and ease of installation with a cost-effective solution for controlling pedestrian movement.
• Verge Pedestrian Gates x 18 units
  Verge’s Pedestrian Gates provide controlled access between segregated areas. Built for frequent use, these self-closing gates enhance traffic flow while ensuring pedestrians can only enter and exit at designated, safe points.

All components were finished in a custom powder-coated colour to match Pinnacle’s branding palette. This attention to detail ensured the final installation delivered both superior safety performance and a refined, professional finish across the facility.

The Result

The completed project transformed Pinnacle’s warehouse into a safer, more efficient workspace. Pedestrian routes are now fully separated from forklift operations, significantly reducing safety risks and improving workflow efficiency.

The solution delivered:

• Enhanced on-site safety with full vehicle-pedestrian segregation.
• Durable, low-maintenance systems designed for long-term performance.
• A cohesive, branded finish that complements Pinnacle’s professional image.

Pinnacle Hardware was highly satisfied with the quality of workmanship, efficient installation, and the striking visual outcome. This project stands as a strong example of how Verge integrates safety, functionality, and design to achieve exceptional results.

Client: Pinnacle Hardware
Provider: Verge Safety Barriers
Products Used: Verge HD Barrier | Verge Eco-Rail | Verge Pedestrian Gates