Industrial warehouse sites increasingly integrate automated systems and material handling equipment (MHE) alongside human workers.
In fact, 76% of work-related traumatic injury fatalities occurred in the warehousing industry, and 42% of those involved a vehicle. This underscores the importance of implementing pedestrian safety solutions that can reliably withstand repeated impacts and accidental collisions caused by forklifts or other material handling equipment.
High-traffic warehouse environments require effective traffic management plans that clearly define vehicle and pedestrian zones, giving workers safe passage between different areas of the facility. The safety infrastructure that supports these plans – such as guardrails, bollards, and barrier systems – is a crucial component of their effectiveness.
Traditional steel guardrails remain a proven choice for withstanding heavy impacts in high-traffic areas, their rigidness upon impact brings the vehicle to a firm halt preventing further damage to any assets on the other side. Alternatively, polymer guardrails like FlexGuard™ offer additional benefits such as energy absorption, which means the guardrail can flex on impact and return close to its original shape.
Every warehouse has its own unique traffic patterns, hazards, and space constraints. The most effective pedestrian safety strategies consider both the type of risk and the best-suited safety infrastructure. By combining the strength of steel systems with the flexibility of polymer in the right locations, businesses can create a comprehensive safety strategy that not only protects assets but also extends the life of their infrastructure and equipment.
Here are three ways steel and polymer guardrails can work together:
1. Main Aisle Protection
High-speed forklift thoroughfares and main transport aisles demand maximum durability. In these areas, polymer guardrails provide a solid, impact-absorbing barrier that protects pedestrians and critical infrastructure from repeated heavy collisions. Positioning these guardrails along the length of main travel routes ensures that both vehicle and pedestrian lanes remain clearly separated and protected. Utilising flexible polymer barriers in this type of area will also maintain concrete integrity and reduce the amount of flooring repairs required after accidental collisions. The flexibility also makes them easier to reposition if workflow changes.
2. Crossing Points and Entryways
Areas where pedestrians are required to cross forklift and material handling vehicle routes – such as near loading docks, entryways, and mezzanine access points – benefit from a hybrid safety setup. Using steel guardrails to protect against direct forklift impacts on approach, and FlexGuard™ polymer railing closer to the pedestrian pathway to absorb collisions and guide foot traffic safely. Be sure to utilise swing gates to control access in and out of these zones, ensuring pedestrians can only enter and exit when it's safe to do so.
3. Packing and Picking Walkway Zones
Use steel partitioning systems to section off areas of the warehouse where picking and packaging zones are situated. Polymer railing can be used on the opposite side of the partitioning to create a designated and visible pedestrian pathway. The polymer guardrail will absorb accidental collisions and guide foot traffic safely. This combination creates a defined workspace for packing stations, picking lines, and conveyor transfer areas while ensuring pedestrians remain protected and visible from forklifts and material handling vehicles travelling to and from the area. The flexibility of the polymer barriers also makes them easier to reposition if the pedestrian walkways had to change or adjust due to growing/changing operations.
Final Word
Protecting pedestrian walkways in high-traffic warehouse environments is not a one-size-fits-all task. The right mix of walkway safety infrastructure not only reduces the risk of serious accidents but also minimises costly repairs to floors, equipment, and infrastructure over time. Whether you're upgrading an existing layout or designing a new facility, a well-planned combination of barriers and partitioning systems will help keep workers safe and operations running smoothly.
If it's been a while since you've reviewed your traffic management plan, now is the perfect time to assess whether your current barriers are positioned and specified for maximum protection. Our team can help you identify the right balance between steel and polymer safety solutions to suit your site's unique needs.
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