Warehouse Safety: Internal Barriers, Racking Guards & Pedestrian Zones
Warehouse environments present one of the highest rates of serious workplace injury in the UK — primarily involving pedestrian/vehicle conflicts, racking collapses, and pedestrians struck by forklifts. Physical barriers are a legally required element of warehouse safety management.
The Legal Framework
- Workplace (Health, Safety and Welfare) Regulations 1992: Require separation of pedestrian and vehicle traffic routes
- PUWER 1998: Require safe use of forklift trucks and other workplace transport
- HSE Guidance Note HSG136: The primary HSE guidance for managing vehicle/pedestrian conflict
Pedestrian Segregation: The Priority
Clear, physical separation of pedestrian walkways from forklift aisles is the single most important safety intervention in a busy warehouse. This requires painted pedestrian lanes AND physical barriers at all conflict points.
Physical Barrier Requirements
- Steel pedestrian barriers at all pedestrian/vehicle crossing points
- Minimum height: 1,100mm for pedestrian barriers, 600mm for vehicle deflection barriers
- Yellow/black colour coding for maximum visibility
- Convex mirrors at all blind corners and intersections — see our convex mirrors range
Racking Protection
Forklift impacts on racking are one of the leading causes of serious warehouse accidents. Racking guards protect the base of racking uprights from direct forklift impact.
| Product | Application | Height |
|---|---|---|
| Single upright guard | End-of-aisle uprights | 400–600mm |
| Double/triple upright guard | Adjacent uprights at aisle end | 400–600mm |
| Aisle end barrier | Full-width aisle end protection | 600–800mm |
| Bay end barrier | Protects full bay width | 600–1100mm |
Implementation Approach
- Conduct a workplace transport risk assessment (HSE guidance HSG136)
- Mark all traffic routes and pedestrian walkways with floor paint
- Install physical barriers at all pedestrian/vehicle conflict points
- Install racking guards at all end-of-aisle and high-risk positions
- Install convex mirrors at all blind corners and intersections
- Brief all staff on new traffic management arrangements
Browse our warehouse safety barriers and convex mirrors.