Mainfreight – Emergency Lighting Upgrade
DGE was engaged to support the electrical maintenance requirements of an industrial site tenanted by Mainfreight. As part of the routine asset management and Building Warrant of Fitness (BWOF) process, DGE identified that the emergency lighting system needed updating to comply with current standards. Over time, changes in warehouse layout and operational flow had impacted the effectiveness of the original lighting design. With the warehouse operating at full capacity, the priority was to update the system to current code requirements without disrupting Mainfreight’s day-to-day activities.
The Challenge
As part of DGE’s routine maintenance and BWOF testing, the annual emergency lighting assessment identified several areas requiring attention. Over time, operational changes within the warehouse, including updated racking layouts and natural wear to existing infrastructure, had affected the performance and placement of some emergency lighting fittings. This resulted in reduced illumination in certain egress areas and a system that no longer aligned with current best-practice design standards.
To ensure the site continued to meet compliance requirements. It supported the safety of Mainfreight’s team, a refreshed emergency lighting design and upgrade were recommended, all to be delivered without impacting daily warehouse operations.
Our Solution
DGE delivered a comprehensive, end-to-end solution:
- Assessment & Design
- Identified all non-compliant circuits and fittings.
- Developed a new emergency lighting design tailored to the current warehouse configuration.
- Coordinated with PFI to ensure design alignment with compliance requirements.
- Managed the process for council re-certification of the upgraded design.
- Installation & Upgrade
- Isolated and removed faulty or non-compliant emergency lighting circuits.
- Installed new compliant fixtures throughout the warehouse.
- Completed additional wiring and system adjustments to support the new design.
- All works were completed during live warehouse operations, protecting business continuity.
- Testing & Certification
- Full system testing carried out to verify performance, coverage, and lux levels.
- Prepared and lodged the documentation required for BWOF and final certification.
Working in a Live Logistics Environment
Mainfreight’s warehouse runs continuously, with constant movement of freight, forklifts, and staff. DGE planned and executed the project around daily operational demands:
- No disruptions to power or warehouse functions
- Safe staged work areas
- Clear communication between DGE, PFI, and Mainfreight
- All installation and testing carried out with zero downtime
This operational sensitivity was essential and demonstrated DGE’s capability in high-activity industrial environments.
Why PFI Chose DGE
PFI required a partner who could handle the entire process, from identifying the issue to delivering a compliant final solution. They chose DGE because:
- DGE offers Design, Build, Maintain under one roof
- Proven expertise in compliance-driven upgrades
- Strong communication with both the landlord (PFI) and tenant (Mainfreight)
- Ability to operate safely within a complex, high-activity site
- Commitment to delivering a future-proofed, fully compliant system
The Outcome
While the project is in its final certification stage, the benefits are clear:
- A fully compliant emergency lighting system
- A modern, accurate lighting design for future maintenance
- Safer and better-defined egress and exit routes
- Reduced compliance risk for PFI
- A warehouse environment that is fit for purpose and future-proofed
- A “single partner” experience for the client through DGE’s integrated delivery model
Key Project Stats
- Project Type: Emergency lighting redesign & upgrade
- Scope: Testing, design, circuit isolation, rewiring, installation, and certification
- Status: Installation complete, awaiting council sign-off
- Environment: Live operational warehouse, zero downtime
Conclusion
This project highlights DGE’s ability to uncover hidden compliance issues, proactively deliver solutions, and work seamlessly in high-demand industrial environments. By managing everything from design to certification, DGE ensured the site is safe, compliant, and future-ready, giving both PFI and Mainfreight confidence moving forward.
