Warehouse environments are among the highest-risk workplaces in the UK. Forklifts, reach trucks, and pedestrians sharing the same space create the conditions for serious and fatal accidents. Correctly specified safety barriers are a fundamental control measure under the Health and Safety at Work Act 1974 and the Management of Health and Safety at Work Regulations 1999.
The Case for Warehouse Safety Barriers: HSE Data
- Workplace transport accidents account for approximately 25% of all workplace fatal accidents in Great Britain (HSE annual statistics)
- Over 5,000 workplace transport accidents reported annually under RIDDOR
- Forklift trucks involved in approximately 1,300 serious injuries and 10 fatalities per year in UK workplaces
- Most common forklift accidents: pedestrian strikes, racking collapse from impacts, and overturning
Relevant HSE Guidance
- HSG136: Workplace Transport Safety: Primary HSE guide — includes physical separation of vehicles and pedestrians
- HSG76: Warehousing and Storage — A Guide to Health and Safety
- PUWER 1998: Requires safe systems of work for forklift operations including physical safeguards
- Workplace (Health, Safety and Welfare) Regulations 1992: Regulation 17 requires safe organisation of pedestrian and vehicle traffic routes
Barrier Types for Warehouse Applications
1. Armco W-Beam Guardrail
Cost-effective and highly visible when powder coated in RAL 1023 Traffic Yellow:
- Industrial-grade W-beam rail
- Bolt-down flanged posts (no ground penetration needed on concrete floors)
- Post spacing: 2.0–2.5m centres
- Rail height: 400mm centred (industry standard for forklift containment); double-rail for higher vehicle types
Cost: £35–£80/m supply; £60–£150/m installed.
2. Polymer/HDPE Safety Barriers
Increasingly popular for pedestrian walkways and machine guarding:
- Impact absorption (unlike rigid steel/Armco)
- Easily repaired section-by-section
- Fully reconfigurable as warehouse layouts change
- Bright yellow for maximum visibility
Cost: £60–£200/m supply; £80–£250/m installed.
3. Racking Protection
- Column guards (post protectors): Wrap around racking upright posts; prevent direct impact damage (£15–£50 per post)
- End-of-aisle barriers: Full-width protection at the exposed end of each racking row — critical protection point (£150–£500 per end installed)
- Rack-mounted barriers: Attach to racking frame; easier in existing warehouses (£80–£250 per bay)
4. Pedestrian Walkway Barriers
- Minimum width: 1,200mm for single-person; 1,800mm for two-way pedestrian traffic (Workplace Regs 1992)
- Barrier height: minimum 900mm
- Colour: RAL 1023 yellow or white for maximum contrast with floor markings
Colour Coding Standards
| Colour | RAL Code | Application |
|---|---|---|
| Traffic Yellow | RAL 1023 | Vehicle exclusion barriers, pedestrian walkways, racking protection |
| Safety Blue | RAL 5005 | Information, disabled access routes |
| Safety Green | RAL 6032 | Emergency exits, first aid, safe areas |
| Safety Red | RAL 3020 | Fire equipment, prohibition zones, danger areas |
| White | RAL 9010 | General demarcation, pedestrian lanes |
Warehouse Safety Barrier Specification Checklist
- ☐ Vehicle circulation routes defined with physical barriers
- ☐ Dedicated pedestrian walkways with physical protection (not just floor markings)
- ☐ All racking upright posts fitted with column guards
- ☐ End-of-aisle barriers on all racking rows
- ☐ Vehicle/pedestrian crossing points have managed gates or stop signs
- ☐ Structural columns protected with Armco or polymer barriers
- ☐ Dock leveller and loading bay edges protected
- ☐ All barriers in RAL 1023 yellow (or per your colour scheme)
- ☐ Barrier fixings checked annually
- ☐ Damaged barriers repaired or replaced immediately
- ☐ Floor markings refreshed when worn
- ☐ Risk assessment updated to record physical control measures
Barriers Co supplies the complete range of warehouse safety barriers across the UK. Browse our warehouse safety range or contact us for a site assessment and specification service.