Case Study: Major Logistics Facility Fit Out

Separating Forklifts and Pedestrians in High-Volume Freight

When you’re running one of the busiest logistics depots in the country, you don’t do safety by halves. In a facility like this, the pressure is always on. Forklifts are zipping around, trucks are loading, and staff are constantly on the move to get freight out the door.

The risk in an environment this fast paced is obvious: heavy machinery and people occupying the same floor space.

The client needed a traffic management solution that would physically separate their staff from their forklifts without slowing down operations. They didn’t want flimsy visual warnings or painted lines; they wanted barriers that could take a hit.

That’s where we stepped in.

The Job

The scope here was massive. We weren’t just protecting a single walkway; we were mapping out safe pedestrian zones across a large portion of the distribution centre.

The challenge was creating a traffic flow that worked for the people on the ground. You can’t just wall everything off, staff need to get to the racks, drivers need access to the floor, and stock needs to move. It had to be safe, but it also had to be practical.

We identified the critical impact zones:

1. Walkways: Needed total segregation from forklift lanes.
2. Racking: The ends of aisles are magnets for impact damage.
3. Building Columns: Structural supports that can’t afford a nudge.

The Solution

We went with our Heavy Duty barrier (HDP) range. For a major freight hub, standard barriers just don’t cut it. The HDP system acts as a physical shield and it flexes on impact to absorb energy, rather than ripping out of the concrete like rigid steel barriers often do.

Here’s the breakdown of the fit-out:

Creating the Green Zone (Segregation)

We installed 410 lineal metres of HDP barrier. This created a clearly defined “Green Zone” for pedestrians. It takes the guesswork out of safety. If you’re behind the yellow rail, you’re safe. If you’re on the other side, you’re in forklift territory.

Controlling the Crossing Points

Barriers are great, but people still need to cross traffic lanes. To manage this, we installed 25 Pedestrian Gates. These aren’t just gaps in the fence; they are inward-opening self-closing gates. They force a person to pause, look, and check for traffic before stepping out. It’s a simple psychological trigger that saves lives.

Protecting the Assets

It’s not just people; the building and stock need looking after too.

• RackPro (51LM): We placed 51 lineal metres of RackPro end-of-aisle protection. This stops a careless turn from a forklift taking out a structural upright.
• Impact Column Protectors (19 units): We wrapped 19 structural columns. Cheap insurance against structural damage.

Flexible Access

For areas that need temporary access or variable zoning, we used 10 Expanding Barriers and 8 Retractable Belt Barriers. This gives the depot manager the ability to close off a loading dock or an aisle temporarily while they work, then open it back up in seconds.

The Outcome

The difference is night and day. The facility now has a clear visual and physical structure.

Walkways are defined. Forklift drivers know exactly where their limits are. Pedestrians can move through the depot confidently, knowing there’s a heavy-duty physical barrier between them and a 3-tonne forklift.

It’s about getting everyone home safe at the end of the shift. This client invested in the best, and now they’ve got a site that sets the standard for logistics safety.

Project Specs

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