Warehouse safety is not a single product problem. A forklift strike on a racking upright, a pedestrian crossing an unmarked traffic lane, a worker going over an unguarded dock edge, these are different hazards that need different solutions, often across the same facility.
Verge manufactures the full range of safety products needed to address every major hazard in a warehouse environment. From heavy-duty forklift barriers and dock gates to racking protection, pedestrian rail systems, and mezzanine fall prevention, we supply and install complete warehouse safety systems across Australia.
Australian WHS legislation requires warehouse operators to implement the highest reasonably practicable level of control for each hazard on site. For most warehouse hazards, that means physical separation, not signage or procedure.
Safe Work Australia is clear: painted lines are not an acceptable control measure for separating pedestrians from forklifts. A barrier stops a forklift from entering a pedestrian zone. A sign asks it not to. When it comes to dock edges, racking stability, and vehicle exclusion zones, the same principle applies. Physical controls are the standard, and Verge products are engineered to meet it.
What makes a warehouse safety solution effective is not just the product, but the system. The right combination of barriers, gates, bollards, and protection products, laid out correctly for the specific traffic flows and hazards in your facility, is what turns a compliance exercise into genuine protection.
HD Barriers and ECO-Rail pedestrian systems create physical corridors that keep workers on foot permanently separated from forklift traffic across the warehouse floor, including at crossing points where self-closing pedestrian gates prompt workers to check before stepping into a vehicle lane.
Dock-PRO gates close off the open dock face when trucks are not present, eliminating the fall hazard at the dock edge and preventing forklifts from driving over the edge during loading operations. Available in heavy-duty steel and medium-duty configurations to suit any dock profile.
Rack-PRO end-of-aisle protectors absorb forklift impacts before they reach racking uprights. Wall-PRO and column protectors protect structural elements and building assets from the daily accumulation of low-speed vehicle contact that causes serious cumulative damage over time.
ECO-Rail handrail systems and edge protection provide compliant fall prevention at mezzanine perimeters, open floor edges, and elevated platforms throughout the facility, meeting Australian fall protection standards without requiring major structural modifications.
The Verge Driver Safety Zone Kit provides a designated safe zone for visiting delivery drivers while they are on site. A four-sided or three-sided barrier enclosure creates a clearly marked area where drivers wait safely while their vehicle is being loaded or unloaded, addressing one of the most frequently overlooked hazards on a busy warehouse site.
Hy-Wall barrier systems provide floor-anchored separation and containment for high-bay storage areas, automated picking zones, and bulk storage configurations where standard barriers are not tall enough or rigid enough for the application.
A new distribution centre at Ravenhall was four weeks from going live and needed barrier protection across the entire facility, with high forklift traffic requiring impact rated products throughout. Verge supplied and installed 220 metres of HD Barrier at 1000mm height, 45 gates, 100 metres of V-Stop floor angle and ECO-Rail through the pedestrian areas. The loading docks required a custom Dock-PRO gate system, designed and manufactured to suit the site. The facility opened on schedule with full protection in place, and Verge has since been named preferred supplier.
Dulux’s Virginia manufacturing site had run out of usable storage space, not because the building was full, but because WHS regulations prevented double stacking pallets near pedestrian walkways. The risk of toppling made it non-compliant, and with floor space already at capacity, Dulux were looking at a $500,000 mezzanine floor as their only option. Verge proposed 48 linear metres of HD Steel Hy-Wall installed at 3 metres high along the walls adjacent to the walkways. The Hy-Wall system anchors to the floor and braces against the wall, creating a rigid barrier that contains pallets stacked at height, eliminating the toppling risk without any structural works. With the barriers in place, Dulux went from single stack to triple stack in the same footprint, tripling storage capacity at a cost of approximately $53,000, saving around $447,000 against the mezzanine quote.
One of the busiest logistics depots in Australia needed physical separation between staff and forklifts across a large portion of their distribution centre, without slowing operations. Verge designed and installed a Green Zone pedestrian system using 410 lineal metres of HDP barrier, creating clearly defined safe walkways. Twenty-five inward-opening self-closing pedestrian gates were placed at crossing points to prompt people to stop and check before entering forklift zones. Column protectors and expanding barriers completed the fit-out. The facility now has clear visual and physical separation across all movement zones.
Pinnacle Hardware’s warehouse had a pedestrian walkway running through a busy pick-and-pack area, with no physical separation between foot traffic and forklifts causing congestion and near-miss risks. Verge conducted a detailed site audit and developed a traffic management strategy using HD Barrier in high-forklift zones, Eco-Rail for pedestrian guidance in lower-risk areas, and self-closing pedestrian gates at controlled crossing points. All components were powder-coated in Pinnacle’s brand colours. The completed project delivered full vehicle-pedestrian segregation with a branded, professional finish across the facility.
Verge partnered with L&H for a complete safety barrier fit-out of their new Redbank distribution facility, joining the project well before construction began to review plans, assess traffic flows and recommend a solution embedded in the site layout from the start. The final installation included HD Barrier for high-traffic forklift zones, Guard Pro for operational walkways, Medium Duty Polymer Barriers in key areas and column protectors at critical impact points. Early involvement ensured sufficient space planning for pedestrian protection areas and AS standards compliance without requiring costly retrofits.
Australia Post’s Blacktown parcel distribution facility needed to safely stack stillages up to four high in selected warehouse zones. Without adequate containment, the stacking created safety risks and restricted available floor space. Verge installed a tiered system of Impact polymer barriers: Medium Duty Barrier to separate pedestrian walkways from forklift zones, 2-metre Hy-Wall for controlled containment of lower stacks, and 4-metre Hy-Wall to enable secure high-bay storage. The 4-metre barriers prevented toppling risk and unlocked over 25% more usable floor area across the facility.
Admil Adhesives undertook a site safety upgrade as their production floor team grew and painted line demarcation was no longer considered an acceptable means of separation. The safety team selected the Australian-made HD Barrier as their chosen barrier system, and Verge completed the comprehensive upgrade across the Mulgrave facility to provide physical pedestrian segregation and forklift traffic management.
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.
Warehouses need safety infrastructure across every zone. Verge manufactures the complete range of barriers, bollards, gates, racking protection, dock safety, and fall prevention products, so you can solve every hazard with one supplier and one consistent system across the facility.
Our team will visit your facility, map the hazards, and recommend the right combination of products for your specific layout and traffic flows. You get a complete solution, not just a product quote.
Verge products are designed to meet Australian Work Health and Safety standards, helping warehouse managers document their hazard controls and demonstrate duty of care to regulators, insurers, and auditors.
Warehouse layouts change. Our modular product range can be reconfigured, relocated, or extended as your facility evolves, without replacing existing infrastructure or starting from scratch.
Local manufacturing means we can respond quickly when a safety gap needs to be addressed, without waiting on international supply chains or extended lead times.
Every warehouse has different hazards, different layouts, and different operational pressures. Tell us what you are working with and we will recommend the right solution for your site.
Contact us today for a free site assessment and quote
*Applies to online orders only. *Cannot be used in conjunction with any other offer **Must purchase within 3 months of receiving the voucher ***Minimum order $1000
"*" indicates required fields
If you need assistance with selecting a product, would like a quote or want to ask a question please call our friendly team on 1800 765 539
