Case Study: New Distribution Centre, Ravenhall VIC

Distribution centre fit out | Ravenhall VIC | Completed March 2026

When a new high-profile distribution centre was planned to go live in Ravenhall in Melbourne’s west, the whole facility required barrier protection before the first pallet moved. Not a section of it. All of it.

The client had used Verge on a previous project in Sydney and wanted the same reliability and product quality for the next facility! Proposals went out to Verge and a range of providers. In the end it came down to two things the client could not compromise on: 1) Certified Barrier that would stand up to high forklift traffic volumes, and 2) A supplier who could design, manufacture and install the lot in four weeks.

Four Weeks to Go Live

Go live dates in distribution do not move. Stock is booked, staff are rostered, trucks are scheduled. If the barrier is not in by then, the site either opens without protection or does not open – neither are desirable outcomes.

We had approximately four weeks from approval to a fully protected facility. Every Verge product is manufactured at our Glendenning facility in NSW, and that is what made the timeframe workable. No overseas lead times and no waiting on a container to land.

What We Installed

Verge HD Barrier: 220 linear metres at 1000mm height, protecting pedestrian walkways and the high traffic forklift zones through the facility.

Verge V-Gates: self closing pedestrian gates fitted for controlled crossing points.

Verge Dock-PRO Gates: gate protection across the loading dock openings, including a custom designed gate system. 45 gates were installed across the site in total.

Verge V-Stop: 100 linear metres of heavy-duty floor angle, stopping pallets and forklift tines from protruding into walkways or making contact with walls.

Verge ECO-Rail: modular handrail through the pedestrian areas.

A Dock Gate System Built for the Site

The loading docks needed something the standard range did not cover, so Verge designed and manufactured a custom Dock gate system to suit the way the docks were set out.

That is the part most suppliers cannot do inside four weeks. Because we manufacture our own product, a custom design does not sit in a queue behind someone else’s order. It gets drawn, made and shipped.

Why HD Barrier

The site runs high forklift traffic, and that was the deciding factor on product selection. HD Barrier is impact tested and rated, so when a forklift makes contact the barrier takes the hit and holds the line. It is solid steel, high visibility, and built to still be doing its job in ten years rather than needing a section swapped out every time something clips it.

V-Stop came in for a different reason. Pallets get stacked close to walls in every DC, and forklift tines reach further than operators expect. The floor angle gives the facility a physical stop at ground level, so walls and walkways stay clear of both. It gave the site peace of mind that stacking near a wall was no longer a repair bill waiting to happen.

The Result

The site opened on schedule with barrier protection in place across the facility. Changes came up during the install, as they do on any new build, and the client’s feedback was that the installers handled them well.

The client has since told us Verge is their preferred supplier going forward on the basis that when they call, the query gets sorted quickly and properly.

Fitting Out a New Facility?

If you are building or commissioning a distribution centre, the cheapest time to get safety infrastructure right is before the site is running. Verge manufactures the full steel and polymer barrier range in Australia, we design custom product where the standard range does not fit, and our installer network covers projects nationally.

Get in touch with Verge Safety Barriers to scope your site.