The shift to battery-powered materials handling equipment is accelerating across Australian warehouses, distribution centres, and industrial facilities. Electric forklifts, order pickers, and reach trucks offer real operational advantages, but they also introduce a new set of safety and infrastructure requirements around how and where they are charged.
Verge designs, manufactures, and installs complete EV charging station solutions for industrial and commercial facilities. From the charging stands themselves to the barriers, bollards, and physical controls that protect the charging area from vehicle impact and unauthorised access, we help you set up a safe, compliant, and operationally efficient charging environment.
A battery charging area in a warehouse or logistics facility is not a passive storage zone. It is an active area where forklifts park for extended periods, charging cables are connected and disconnected, battery changes are carried out, and workers move around powered equipment on a regular basis.
The risks are specific and well understood. Forklifts approaching the charging area at speed can strike charging stands, damage cabling, or hit parked vehicles. Workers performing battery changes are exposed to vehicles manoeuvring in tight spaces. And in facilities where charging happens in or adjacent to high-traffic forklift corridors, the potential for a collision between a moving vehicle and a stationary charging setup is real.
Australian WHS legislation requires facility operators to identify and control these hazards. Physical barriers around the charging area define the zone, protect the equipment, and separate workers performing maintenance tasks from moving vehicles. Verge’s integrated approach covers both the charging infrastructure and the safety systems around it.
The charging stands, cabling, and battery handling equipment represent significant capital investment. Barriers and bollards around the charging bay perimeter prevent forklifts from striking equipment during approach and departure, protecting both the charging infrastructure and the vehicles being charged.
Forklifts approaching the charging bay need a defined, controlled approach path. Wheel stops and parking guides position vehicles correctly at the charging stand, preventing overruns into adjacent areas and ensuring cables are not stressed or damaged by incorrect parking alignment.
Battery changes require workers to be on foot in close proximity to heavy equipment. Defined pedestrian zones and barriers around the battery change area separate workers from moving forklift traffic during this task, which is one of the highest-risk activities in a charging area.
Charging cables on the floor create tripping hazards and are vulnerable to forklift damage. Proper cable management infrastructure, combined with defined vehicle paths around the charging area, keeps cables off the floor and out of the vehicle path.
The charging area as a whole needs a clearly defined boundary that controls access during charging operations and prevents unauthorised vehicles or pedestrians from entering the zone. Expandable barriers and bollards provide flexible access control that can be adjusted as operational needs change.
Lead-acid battery charging produces hydrogen gas, requiring adequate ventilation and defined exclusion zones around active charging. Physical barriers help enforce these exclusion zones, keeping ignition sources and workers away from the immediate charging area during the charging cycle.
Every Verge product is manufactured at our Glendenning, NSW facility, meaning faster delivery, local technical support, and products designed specifically for Australian conditions and WHS compliance requirements.
Verge manufactures both the charging station infrastructure and the barriers, bollards, and protection products that make the charging area safe. You get a fully integrated solution from one supplier, designed to work together from the start.
Verge products are designed to meet Australian Work Health and Safety standards, helping facility managers document their hazard controls around charging areas and demonstrate duty of care to regulators and insurers.
Verge charging stations and safety products are built for the demanding conditions of a working warehouse or logistics facility. They handle the daily contact, vibration, and environmental conditions that office-grade EV charging equipment cannot.
As your electric fleet grows, your charging infrastructure needs to grow with it. Verge's modular charging station range and barrier systems can be extended and reconfigured to accommodate additional vehicles without a full redesign of the charging area.
Local manufacturing means we can respond quickly when you need to commission a new charging area or upgrade an existing one, without waiting on international supply chains or extended lead times.
Every charging area has different layout requirements, fleet sizes, and operational constraints. Whether you are setting up a new charging bay or upgrading an existing area, Verge can help you design a safe, compliant, and efficient solution.
Contact us today for a free site assessment and quote.
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