Case Study: Toyota Distribution Centre, Redbank

A Repeat Client – and a Custom Hy-Wall Build

When Toyota approached us about their new Distribution Centre in Redbank, QLD, it was based on experience, not marketing. They had used our products for six years at their previous site and had seen the performance firsthand. So, when plans began for the new facility, Verge was included from day one.

That’s the kind of trust you earn over time, not something you can manufacture.

Getting Involved Early

Toyota’s builder, Deluca, engaged us during the early planning phase, well before any concrete was drilled. That timing mattered. It allowed us to review the layout in detail, understand how the site would function each day, and recommend the most suitable barrier system for every zone.

In a distribution centre, risk isn’t uniform. A busy forklift corridor calls for a very different solution to a pedestrian pathway near dispatch. Being involved from the outset meant we could specify the right barrier for each application, instead of trying to adapt a solution once the slab had already been poured.

The Custom Hy-Wall Solution

One of the key aspects of this project was Toyota’s requirement for a customised Hy-Wall barrier. Standard off-the-shelf options weren’t suitable for several areas within the facility, so we worked closely with their team to design and manufacture a Hy-Wall configuration tailored to their specific operational needs. The result was a solution built around how the site functions, not a compromise forced to fit.

This is something we do regularly for larger projects. When a client’s got a unique challenge, such as an unusual height requirement, a non-standard layout, or a specific segregation need, we can design a solution to fit those exact requirements.

The Installation

It was a substantial project. Here’s what was delivered across the facility:

Pedestrian Separation

We installed 1,692 lineal metres of Eco-Rail across the facility. That’s a lot of pedestrian handrails, but in a distribution centre of this size, you need clear, physical separation between foot traffic and forklift zones. The Eco-Rail system is modular, so it adapts to the floor layout without needing custom fabrication for every turn and corner.

Alongside the Eco-Rail, we fitted 105 Pedestrian Gates. In a facility with this many crossing points, self-closing gates are critical. They force people to stop, look, and make a conscious decision before stepping into a traffic zone.

Vehicle Barriers and Guardrail

For the heavier vehicle zones, we installed 813 lineal metres of V-Stop and 415 lineal metres of Guard-PRO Single. These products protect infrastructure, racking, and personnel from forklift impacts. The V-Stop handles the boundary lines between vehicle and pedestrian zones, while Guard-PRO protects assets and defines traffic lanes.

Custom Mesh Barriers

This is where the project really stepped up. We manufactured and installed 374 lineal metres of custom mesh barrier at 2.5 metres high, along with a further 84 lineal metres at 8 metres high.

The 8-metre mesh barriers are a serious piece of infrastructure. When segregation is required at that height, it usually means high-stacked goods or specific containment zones are involved. Each section was custom-built to Toyota’s specifications and installed as part of the complete barrier package for the facility.

The Numbers

Why It Worked

The straightforward answer is experience. After six years of using our barriers at their previous site, Toyota knew exactly what to expect. They’d seen how the systems performed in a live environment. They understood the durability, the reliability, and our ability to deliver custom solutions without delays.

Bringing Deluca and our team together early meant the barrier layout was developed in parallel with the building design. It wasn’t added at the end to solve a problem. It was planned as part of the solution from the beginning.

That approach results in safety infrastructure that supports day-to-day operations, rather than getting in the way of them.

Planning a Distribution Centre Fit Out?

We work alongside builders, project managers and facility owners from the early design stage through to final installation. Being involved upfront allows us to recommend the right systems, avoid costly changes later, and make sure safety is built into the layout from the start.

If you’re planning a new facility or a major upgrade, have the conversation early. It will make a genuine difference to how the finished site performs.

Request a Quote or call us on 1800 765 539 to talk through your project.