If you're searching for alternatives to metal barriers, you're probably already familiar with the downsides: rust, floor damage, expensive repairs, and layouts that can't adapt when your operations change.
You'll be pleased to know you're not stuck with steel. UK warehouses, factories, and distribution centres are increasingly moving toward barrier systems that protect people and infrastructure without the headaches that come with traditional metal.
This guide breaks down the main alternatives, explains where each option works best, and helps you decide which approach suits your facility.
Contents:
Steel barriers rust. Everyone knows this. But what surprises most facilities managers is where and how fast it happens.
Metal barriers have been the default choice for decades. They look solid. They feel permanent. But that permanence comes with problems.
Steel is rigid, which means it transfers impact energy directly into floors, fixings, and vehicles. A single FLT collision can crack concrete, loosen anchors, and bend the barrier itself - leaving you with repair bills that quickly add up. We've visited sites spending £20,000 or more annually just on floor repairs around their steel barrier systems.
Then there's corrosion. In wash-down environments, food manufacturing, or outdoor loading bays, rust can compromise a barrier's structural integrity within months. Under PAS 13:2017 - the industry code of practice for safety barriers - systems must maintain their rated performance over time. A corroded barrier doesn't meet that standard.
The Workplace (Health, Safety and Welfare) Regulations 1992 require employers to organise traffic routes so vehicles and pedestrians can circulate safely. Meeting that duty means choosing barriers that actually perform - not just ones that look the part on day one.
Polymer barriers are the most direct replacement for steel. They're engineered for the same job - physical separation between pedestrians and vehicles - but they work in a fundamentally different way.
How they differ from metal:
Where steel resists impact through rigidity, polymer absorbs it through flexibility. When a loaded FLT strikes a polymer barrier, the material deforms elastically, dissipates the energy, and returns to its original shape. The floor stays intact. The vehicle takes less damage. The barrier keeps working.
This isn't a compromise on strength. Quality polymer barriers are tested to PAS 13 standards with documented impact ratings, meaning they offer verified protection rather than assumed toughness.
Practical advantages:
Polymer doesn't rust, corrode, or require repainting. It's non-porous, so it cleans easily and meets hygiene standards in food and pharmaceutical environments. Modular designs mean you can reconfigure layouts without specialist tools or floor work - a significant benefit when operations change.
One major logistics network saw workforce incidents drop by 20% and maintenance costs fall by £3 million annually after switching from metal to polymer systems across their sites.
Best suited for:
High-traffic FLT areas, food and beverage manufacturing, pharmaceutical facilities, cold storage environments, and any site where layouts change regularly.
Read more: Metal Barriers vs Polymer Barriers - What's the Difference?
Not every situation calls for a physical barrier. In some environments, visual segregation is more practical - and LED projected floor markings offer a modern alternative to painted lines.
How they work:
Ceiling-mounted LED units project bright, consistent markings onto the floor surface. Unlike paint, they don't fade, scuff, or wear away under heavy traffic. They stay visible in poor lighting conditions and can be repositioned without any floor work.
When they make sense:
LED markings work well in areas where physical barriers would obstruct operations - wide transport aisles, crossing points, or zones that need to flex between different uses. They're also effective as a complement to physical barriers, reinforcing walkways and hazard zones with high-visibility guidance.
The HSE's workplace transport guidance HSG136 emphasises the importance of clearly marked pedestrian routes. LED systems deliver that visibility without the maintenance burden of traditional floor paint.
Limitations to consider:
LED markings provide visual guidance, not physical protection. They won't stop a vehicle. For high-risk areas where impact protection is essential, they work best alongside polymer barriers rather than replacing them.
Best suited for:
Pedestrian crossing points, flexible warehouse zones, areas with frequent layout changes, and sites where painted markings wear quickly.
The most effective safety layouts often combine multiple solutions. Hybrid systems use physical barriers where impact protection matters most, supported by visual guidance in transitional zones.
What this looks like in practice:
A typical hybrid approach might include polymer barriers along primary walkways and around high-value assets, LED projected crossings at pedestrian-vehicle intersection points, and self-closing safety gates where walkways meet FLT routes.
Paul Mann, Hub Operations Manager at DPD, described the impact after implementing an integrated system at their Superhub:
"It revolutionised the way we operate our lines."
Why hybrid works:
Different areas of your facility carry different risks. A narrow aisle beside heavy racking needs robust physical protection. A wide crossing point might only need clear visual guidance and controlled traffic flow. Matching the solution to the specific hazard gives you better protection without over-engineering every zone.
Best suited for:
Large distribution centres, complex manufacturing layouts, sites with mixed vehicle and pedestrian traffic, and facilities planning phased safety upgrades.
The best metal barrier alternative depends on your specific environment, risks, and operational needs. Here's a simple framework:
Consider polymer barriers if: Your site has regular FLT traffic, you're spending significant time and money on barrier maintenance, your layouts change periodically, or you operate in a corrosive or hygiene-critical environment.
Consider LED floor markings if: You need flexible zone marking, painted lines wear out quickly, you want to enhance visibility at crossing points, or physical barriers would obstruct workflow.
Consider a hybrid approach if: Your facility has varied risk levels across different zones, you want maximum protection in critical areas with lighter-touch solutions elsewhere, or you're upgrading an existing layout in phases.
The right starting point is understanding what's actually happening on your floor - where the risks are, how traffic flows, and where your current approach is falling short.
Every site is different. The layout that works for a cold storage warehouse won't suit a busy manufacturing plant, and a solution designed for a single depot might not scale across a national network.
That's why we start with a proper site assessment - walking your floor, mapping your traffic patterns, and identifying where the real risks are. From there, we can recommend the right combination of barriers, markings, and controls for your specific operation.