BMW - Impact Resistant Barriers

Who are BMW?

BMW Group operates advanced manufacturing and logistics facilities across the UK, supporting precision automotive production at scale.

The Hams Hall site plays a critical role in engine manufacturing and internal logistics, where heavy-duty material handling equipment operates continuously within tightly controlled environments.

Maintaining infrastructure protection in high-impact zones is essential to safeguard both operational continuity and structural integrity.

BMW's Challenges

During a site review, two key high-risk areas were identified where existing protection systems were required.

Area 1

Approximately 30 linear metres required impact protection capable of absorbing the force of a five-ton forklift truck travelling at 7mph.
Two lifting gates were also required within this barrier run to maintain operational access while preserving segregation.

Area 2

Low-level steel protection previously installed around conveyor systems had deteriorated and was being repeatedly damaged beyond repair.
A more resilient solution was needed to withstand ongoing MHE interaction without constant replacement.

Structural column protection barrier in warehouse environment

Industrial warehouse safety infrastructure in automotive plant

Heavy-duty warehouse barrier for MHE traffic control

Polymer safety barrier protecting high-traffic forklift zone

Low-level polymer barrier protecting conveyor system in factory

Low-level impact wall protection barrier installed in forklift zone

Automotive production asset impact protection system

The Solution:

Clarity Safety designed and installed a bespoke protection system across the highest risk areas, combining:

1. High-impact-resistant polymer barrier systems rated for heavy forklift interaction

2. Integrated sliding gates within the primary barrier run

3. Low-level impact protection to shield conveyor infrastructure

4. Column protection to safeguard structural assets

The selected polymer systems provided energy absorption through controlled flex and rebound, reducing structural stress compared to rigid steel alternatives.