Choosing the right safety barrier for your facility can be confusing.
We’ve devised a five-step barrier assessment guide for you to follow. Finding the right barrier type has never been easier.
1. Safety
Visibility
Quite simply, your best defence in a fast moving environment is being seen.
A warehouse manager once said: “High visibility barriers changed our people’s awareness. They have consciously and subconsciously improved habits, which now results in far fewer impacts.”
The high visibility feature heightens awareness and reduces accidental impact damage. You should aim to create a culture of safety first with your employees.
A high-vis yellow guardrail will safely define and restrict pedestrian access to hazardous and dangerous areas.
Accidents
Protruding edges, sharp corners, rough steel, chipped powder coat can cause undue harm and injury to personnel. The slightest nick to sensitive skin could mean an infection to the staff member.
The soft rounded profile that an HDPE flexible barrier offers, is far less likely to cause injury to your people.
Protection
“Barrier coverage” describes the surface area a barrier protects. In most countries, the minimum height for safety barriers/guardrails is 900mm from the floor.
Some barriers have ground level protection beams, some have double level protective beams, and some have a full height (usually up to 1100mm high)
Light duty hoop barriers do not perform well in the case of protection coverage – they are primarily used for delineation, highlighting and restricting access.
Steel crash barrier guardrails fair well in this category. With different posts available, beams can be positioned at different heights, there’s also a handrail add-on. Steel Crash Barrier/Guardrail Guide
HDPE Barriers will give you maximum protection levels, for example, warehouse pedestrian walkways.
2. Damage & Collisions
Durability
“Durability is the ability to withstand wear, pressure, or damage, without significant deterioration in quality”
How long will my barrier last? Well, that depends on a few external factors.
Steel barriers: Ask yourself, are the barriers galvanised, is it likely to rust, is it powder coated, or painted? How thick, and what grade steel has been used to manufacture the barrier?
Polymer barrier: Stronger than steel and independently tested for impact. Is the product UV stabilised, what life span can I expect? Also, familiarise internal components and design.
As part of your Health and Safety policy, you should implement a regular check on the integrity of the barrier systems. Has there been a major impact? Do you need to replace the system or call your local maintenance team?
Barrier impact test report example excerpt:
“equivalent to an impact from a 6,500 lb [2948 kg] vehicle traveling at 4.5 mph [7.2 km/h]. In testing, the barrier was subjected to higher loadings and further deflections.”
Vehicle Protection
Forklifts and material handling equipment are an expensive investment, consider the damage a barrier type may inflict on your machinery.
Inexperienced and under-trained forklift operatives are one of the most dangerous hazards to your staff, vehicles and property.
Impacts and accidents are inevitable, therefore selecting a hi-vis polymer safety barrier that doesn’t have acute corners or hard edges will minimise superficial damage to your forklift.
Steel on steel impact = scratches to both vehicle and the barrier.
Impacts
Different impact barriers will absorb deflected impacts at varying angles better than others.
To simplify the impacts that may be happening in your premises, prepare a risk assessment – label the type of impact into light, medium or heavy impact.
- LIGHT impact is classed as general wear & tear from pedestrian or light goods trollies
- MEDIUM impact is a stacked pallet truck
- HEAVY impact is a forklift, van or truck
3. Upkeep & Hygiene
Maintenance
Maintenance is an integral part of every business.
Is the barrier scratched – can you repaint it with the matching colour?
Do you need to touch up rust spots?
If you choose the latest polymer designs, then a quick wipe of clean damp cloth will drastically cut your maintenance budgets over time and keeps your premises looking newer for longer.
As part of your Health and Safety policy, you should implement a regular check on the integrity of the barrier systems. Has there been a major impact? Do you need to replace the system or call your local maintenance team?
A maintenance manual (O&M manual) should be a key part of your companies safety policy.
Material Types
“Decisions decisions – should I choose a metal barrier or a polymer barrier?”
Ask yourself, will the barrier contribute to your overall health and safety policy.
Polymer HDPE Barriers are the preferred option especially where hygiene is at the forefront eg. pharmaceuticals, food & drink processing, healthcare, cosmetic manufacturing industries to name a few.
Contamination is a constant worry, so pick a product that is easy to keep clean.
Traditional metal barriers may have slight corrosion, starting to chip (flaky paint), and often get overlooked if a regular cleaning schedule is not maintained.
Building & General Repairs
Heavy duty impacts will likely ‘rip up’ your floor.
Industrial grade floors are extremely expensive to install and expensive to repair (1sqm could cost up to €1,000)
With this in mind, consider which barrier system is least likely to damage your floor following impact, and least likely to cost you unforeseen repair costs.
An incorrectly placed barrier is a serious subject, a collapsed wall or pallet rack could potentially be fatal, make sure this doesn’t happen.
4. Installation
Difficulty
How difficult is it to install a Safety Barrier?
Naturally, this is heavily dictated by experience and training.
If you are familiar with power tools and can follow instructions, most maintenance persons can install a barrier without too much difficulty.
Considerations:
If I’m installing a steel barrier – how heavy it is? Do I need more than 1 person to assist in manoeuvring the material?
Should I use a ‘bolt down’ fixture, or invest in a ‘cast in’ option…
What is the substrate type? Is the substrate in good condition. Are there underlying services to be aware of.
Do I have the required power tools, if I don’t, how much will it cost to hire or purchase new ones? Do I need specialist equipment – do I need a cert to use specialist equipment.
Creating Perimeters
A Standard Metal Hoop Barrier is not usually considered modular – as it is usually fabricated in single units. Add on mods are generally installed ‘side by side’.
The graphic below shows a modular forklift barrier protecting an extra-large warehouse structural column where a standard column guard wouldn’t fit.
“Modular – constructed with standardised units or dimensions for flexibility and variety in use”
Both the heavy-duty crash barrier and the polymer barriers are considered modular. You can adjust the lengths required during installation. There are accessories available to create bends, returns and terminal ends.
Removability
Can I re-use and relocate an existing barrier if I decide to re-organise my premises.
What fixings / installation has been used. Will my floor be ok if I relocate a barrier?
Choose a removable barrier that lends itself to future relocation, over a static solid option.
In the pharmaceutical industry, warehouse space is often downsized to make room for new laboratory space. Laboratory space is more profitable.
5. Conclusion & Price Range
In conclusion, check out the barrier assessment cheat sheet below, this will give you an understanding of when to use what barrier type where.
Remember, safety is paramount in every business, and barriers are just the tip of the iceberg but why not start here.
Author notes: Regardless of which barrier you choose, the ultimate performance is determined by the adequacy of the surrounding ground.
If you are implementing a full warehouse safety policy, you should always perform a Risk Assessment and consult a professional safety expert.
This content is provided for informational and guidance purposes only.
Barrier Assessment Cheat Sheet
Heavy Duty Crash Barrier
Material: Plain galvanised steel 3mm
Price Range: Budget – Mid
Application: Car parks, service yards, perimeter protection, rack ends
- Traditional style, easy to extend, heavy duty, modular
- Two man installation job due to barrier weight
Yellow Hoop Barrier
Material: Mild steel, powder coated
Price Range: Budget – Mid
Application: Delineation, light-duty impacts
- Light, easy to install, price friendly
- Too light, easily scratched, single beam protection means poor safety coverage. Not adjustable
Galvanised Steel Access Barrier
Material: Galvanised & powder coated
Price Range: Budget-Mid
Application: Mechanical & electrical control protection (e.g loading bay switches, downpipes, etc)
- Removable cross beams allow for access when required. Good protection and coverage. Easy to install
- Powder coated elements may chip or scratch
Polymer Flexible Barrier
Material: Polymer with iron core and rubber damper floor protection technology
Price Range: High-end Certified
Application: Suited to almost every aspect of your premises that requires heavy-duty protection and the utmost safety
- High-vis, no repaint. Easy to clean, relocatable. Hidden fixings and polymer are easy to clean. Engineered and certified to take multiple forklift hits.
- Suited to concrete install only
Need exact prices or barrier advice?
