Case Study: McNab – Cold Storage New Build

Loading dock and asset protection for a large-scale cold storage and logistics new build.

THE CHALLENGE

McNab were appointed to construct a new refrigerated distribution centre featuring a large, cold storage facility with multiple loading docks. The dock design featured a concrete step-down which allowed for ease of unloading from a range of different size vehicles – but also creating a fall hazard internally.

The risk was straightforward but serious. Forklifts moving between loading docks and storage could potentially misplace pallets on/over the set-down – or worse, potentially drive over the edge in a case of loss of control! There was also the external perimeter to address: vehicle traffic circulating around the building needed intelligent barrier placement to maximise asset protection and assist with clear traffic control.

The project also presented a visual challenge. The specification called for pedestrian handrail and heavy-duty guard rail to run side-by-side in some areas. At standard heights, the two barrier types sit at different levels, which creates a mismatched look and the client wanted a uniform barrier height.

THE SOLUTION

Verge specified Guard Pro + Handrail along the full length of the internal dock face: 93 linear metres of single Guard Pro with handrail, installed at each loading bay to contain forklift traffic and prevent any contact with the dock edge. The Guard Pro absorbs and redirects forklift impact, protecting workers, dock equipment and the building structure.

Externally, a further 136 linear metres of Guard Pro was installed around the building perimeter. This keeps vehicle traffic clear of facility assets and provides a physical separation between truck movements and pedestrian zones.

To resolve the height mismatch between guard rail and pedestrian handrail, Verge custom-fabricated the pedestrian handrail sections to match the height of the Guard Pro Handrail. The result is a continuous, consistent barrier line across the entire dock face. One height. No visual break.

Eight pedestrian gates and eight custom access stairs were also installed to provide safe, controlled access between the dock level and the main storage floor level.

The full system was finished in Verge safety yellow powdercoat over Hot Dip Galv throughout. This gives workers and forklift operators a clear, consistent visual boundary whilst ensuring these steel barriers are built to last in a rigorous cold storage environment.

PRODUCTS USED

Guard Pro with Handrail

229 linear metres installed across internal dock face and external perimeter. Single Guard Pro with integrated handrail, designed for forklift impact protection in high-traffic warehouse and logistics environments.

Eco Handrail

48 linear metres installed. Custom-fabricated to match Guard Pro handrail height, creating a continuous, uniform barrier line along the dock face.

Pedestrian Gates (x8)

Controlled access points integrated into the barrier line at dock entry points.

Custom Access Stairs (x8)

Fabricated to suit the dock step-down height to provide safe pedestrian access between levels.

THE OUTCOME

The McNab built facility now has a complete barrier system that addresses every movement risk on site: dock-edge protection, forklift safety, perimeter vehicle barriers and safe pedestrian access.

The installation covers 229 linear metres of guard rail, 48 linear metres of matching handrail, 8 access gates and 8 stairs. All in standard Verge safety yellow, all built to handle forklift impact without needing replacement after every incident.

Specifying a similar project? Talk to the Verge team.

vergesafetybarriers.com.au