Aldi

Global supermarket chain Aldi required a warehouse safety fit-out for their newly established warehouse and distribution centre in Truganina Victoria. Barrier Group was engaged to conduct a full safety fit out addressing asset protection, environment control and pedestrian-vehicle safety.

Location: Aldi
Complete: July 2025
Visit: https://www.aldi.com.au/

The Problem

To support stronger outbound logistics and store replenishment across their network of franchise stores, the German supermarket chain relocated to a 27,468 square metre distribution centre in Truganina Victoria.

To ensure the facility was prepared for full operation, Barrier Group was engaged to provide a turn-key safety experience.

Through early consultation and site evaluation, conducted by a dedicated Barrier Group Account Manager, the following key safety objectives were identified in line with the traffic management plan:

Pedestrian-Vehicle Segregation: Pedestrian walkways often operated adjacent to forklift travel routes;
Access Points: Pedestrian walkways had to intersect with vehicle travel routes at many points throughout the facility;
Structural Protection: A number of exposed structural columns and other building infrastructure such as walls and roller doors faced potential risk of impact in areas of increased vehicle traffic; and
Compliance and Standards: The facility needed to ensure that all safety installations, such as clearances around fire hose reels, met relevant Australian Standards, including AS 2441:2005.

The Solution

To address these priorities, Barrier Group designed, manufactured and installed a turn-key safety solution that would ensure asset protection, environment control and pedestrian safety.

The full scope of the safety product fit-out included:

Asset Protection

Heavy-Duty W-Beam Guardrail was installed along the exterior walls in between roller doors, segregating the building infrastructure from in-transit vehicle traffic.
Strategic placement of permanent surface-mount bollards to safeguard structural columns and provide clearance around fire hose reels, ensuring adherence with AS 2441:2005.
Heavy-Duty Foam-Filled Column Cushions were installed around adjacent structural columns to help prevent damage from potential forklift impact. The heavy-duty model is filled with high-density injectable expanding foam, dramatically enhancing impact absorption.
Menni Asset Protection was used to complement pre-existing guardrail safety infrastructure and offer lower-level impact protection. Please note, Menni is now a discontinued product range and replaced by the FlexGuard™ Floor Guard.

Environment Control

Powder coated Truck Wheel Stops were installed to assist truck drivers in achieving proper parking alignment and to protect the building's apron and infrastructure.

Pedestrian Guidance

More than 160 hours of line marking was used to define pedestrian walkways, delineate truck parking bays and outline pallet racking edges. The line marking in total consisted of 2,780 m of general demarcation white lines; 1,000 m of yellow lines to delineate hazardous areas, and 38 m² of red chevrons, creating clear directional travel patterns.

Barrier Group and Aldi worked closely on the Truganina project, addressing the common complexities of a large-scale warehouse and logistics facility safety fit-out.