78 FENCE CASE STUDIES

Industrial Gate Automation & Safety Enhancement for Furniture Distribution Facility

Client:

JB Hunt Freight

Project Type:

Commercial

Scope:

Gate Automation and Conduit Installation

Client Profile

A large furniture distribution center in the Northeast U.S., handling high-volume truck traffic for loading and unloading goods from shipping containers.

The Challenge

Non-Operational, Unsafe Entry/Exit System

Before the project began, the facility faced critical logistical and safety challenges:

  • Two 30–32 ft gates (entry and exit) were both malfunctioning.
  • Trucks entered and exited through the same gate, leading to traffic inefficiencies and safety concerns.
  • The gate operators were outdated and non-functional.
  • There was no system in place to regulate or signal safe passage for trucks.
  • No protective bollards or communication systems to prevent gate equipment damage or ensure secure operation.
  • Gate areas lacked pedestrian-friendly and driver-appropriate interfaces for check-in and check-out procedures.

These shortcomings disrupted daily operations and posed a significant risk of equipment damage and safety incidents, especially with large 18-wheelers regularly entering the premises.

The Transformation Process: Structured, Secure, and Smart Access

Our team delivered a comprehensive solution focused on operational efficiency, vehicle safety, and equipment protection. The scope of work included:

Step 1: Assessment and Planning

  • Conducted a detailed inspection of both gate systems.
  • Analyzed traffic flow patterns to determine the best placement for safety and communication equipment.

Step 2: Gate Operator Upgrade

  • Installed new, commercial-grade gate operators on both entry and exit points.
  • Integrated a smart lighting system:
    • Solid Red Light: Indicates the gate is closed.
    • Flashing Red: Signals gate is in motion—drivers must wait.
    • Solid Green: Indicates it is safe to proceed—gate is fully open.
  • These visual cues now provide clear driver feedback, reducing gate collisions and confusion.

Step 3: High-Security Bollard Installation

  • Constructed deep-set, reinforced bollards using crash-barrier principles:
    • 2-foot deep piers, 18 inches in diameter.
    • Steel-reinforced concrete pad (2 feet thick) connects all bollards as one immovable unit.
    • Bollards are filled with concrete and covered in polyethylene jackets—no painting required, long-lasting high-visibility yellow finish.
  • Designed to withstand heavy impacts, these bollards protect critical infrastructure such as gate operators, cameras, and card readers.

Step 4: Communication Pedestal System

  • Installed dual-height access pedestals to accommodate both:
    • Passenger vehicles
    • Tall commercial trucks
  • Each pedestal includes:
    • Camera systems
    • Card readers
    • Intercoms for remote check-in/check-out

Step 5: Underground Conduit & Integration

  • Ran low-voltage and high-voltage conduits from gates to the main building.
  • Utilized lift equipment to install infrastructure within the building’s control systems.
  • While the client managed wire installation, we ensured all electrical and data infrastructure was properly integrated and future-ready.

The Result: A Safer, Smarter, and Stronger Entry System

The results of the transformation are immediately visible and operationally impactful:

  • Streamlined Traffic Flow: Separate lanes and automated signals reduce confusion and congestion for truck drivers.
  • Improved Safety: Bollards protect both infrastructure and personnel; lighting system prevents accidental gate impact.
  • Durability and Low Maintenance: Polyethylene bollard covers and deep concrete reinforcement minimize upkeep and extend the system’s life.
  • Enhanced User Experience: Dual-height pedestals ensure ease of access for all vehicle types, improving driver satisfaction and operational efficiency.
  • Future-Proof Infrastructure: Robust conduits and pedestal systems allow for future tech upgrades or system expansions.

This transformation turned a high-risk, outdated entry system into a safe, intelligent, and reliable access point for the client’s busy logistics hub. Through thoughtful engineering, innovative problem-solving, and careful attention to traffic and safety needs, the project delivered long-term value and peace of mind for the client’s operations team.

Expert Insight: Crash Barrier Technology Applied

A standout feature of this project was the application of crash-barrier engineering techniques to bollard installation—bringing high-security principles into a commercial environment. This knowledge ensured that the safety systems not only looked secure but were engineered to withstand real-world impacts from even the heaviest vehicles.