Where Do Safety Barriers Go? A Zone-by-Zone Placement Guide for UK Warehouses

You've finally got management to agree that barrier investment is necessary. That's not easy - you've made the case, justified the spend, and secured approval.

Then comes the next question: "So where exactly are these going?"

Suddenly you're staring at a floor plan, wondering if the barriers should run alongside the racking, protect the doorways, or segregate that corner where FLTs always cut through. Put them in the wrong place and you've just spent thousands on barriers that either don't protect the significant risks or create new bottlenecks.

We see this hesitation all the time during site assessments. Warehouse managers know they need barriers, but the placement decisions feel uncertain.

Here's what makes it simpler: barrier placement that follows clear principles based on PAS 13 guidance, HSE regulations, and how your traffic really moves. Once you understand the framework, the decisions make themselves.

This guide walks you through every critical zone in your warehouse, explaining exactly where barriers belong and why.

Contents:

1. Where Should Barriers Go in Pedestrian Walkways?
2. How Do You Protect Racking and Storage Areas?
3. What Barrier Placement Works Best at Loading Bays?
4. Where Do Barriers Belong Around Doorways and Entrances?
5. How Should You Position Barriers at Vehicle Crossing Points?
6. What About High-Traffic Intersections and Corners?

Where Should Barriers Go in Pedestrian Walkways?

Pedestrian walkways need the most careful planning because they're where your team spends a large portion of their time on foot. HSE data shows that around 5,000 people are injured annually in workplace transport incidents, with a significant proportion involving pedestrians being struck by moving vehicles.

Under the Workplace (Health, Safety and Welfare) Regulations 1992, you must provide safe pedestrian routes that are physically separated from vehicle traffic wherever reasonably practicable.

The 1-Metre Rule

PAS 13:2017 states that safety barriers are required between pedestrian walkways and vehicle routes if they're closer than 1 metre and not separated by a raised kerb. This is the benchmark used by HSE inspectors and external auditors.

Your barriers should run continuously along walkways, protecting pedestrians from FLT routes. Don't rely on painted lines alone - they fade, get ignored, and offer zero impact protection.

Minimum Walkway Width

PAS 13 recommends pedestrian walkways should be at least 1 metre wide, though 1.2 metres is better for wheelchair accessibility and comfortable two-way traffic.

Polymer pedestrian barriers work particularly well here because their slim profile maximises usable space while maintaining full PAS 13 impact protection. Unlike bulky steel systems, they don't eat into your aisle width or create trip hazards with protruding baseplates.

How Do You Protect Racking and Storage Areas?

Racking damage is a common issue we see during site assessments. A single FLT impact can compromise an entire bay, putting both products and people at risk.

Barriers should be positioned at vulnerable racking points:

Rack End Protection

The exposed ends of racking runs take the most impacts. Position barriers at least 300mm away from the rack uprights to create a protective buffer zone. This gives the barrier room to flex on impact without transferring force to the racking structure.

Aisle Intersections

Where racking aisles meet main thoroughfares, corner impacts are frequent. Install barriers that wrap around these corners to protect both the racking and guide vehicle traffic safely through turns.

High-Value Storage Zones

If you're storing temperature-sensitive goods, hazardous materials, or high-value inventory, barrier protection becomes even more critical. The cost of damaged stock often exceeds the cost of the barrier system itself.

Clarity's rack protection systems are specifically designed to absorb frontal and lateral impacts without requiring floor fixings, which preserves your concrete and maintains maximum floor space.

What Barrier Placement Works Best at Loading Bays?

Loading bays are high-risk zones where vehicles reverse, doors open unexpectedly, and people work near significant drop hazards.

Dock Edge Protection

Position barriers along the edges of loading docks to prevent vehicles from accidentally reversing too far. Loading bay protection systems like dock gates provide a physical barrier that prevents slipping, falling, or vehicle tipping near open loading areas.

These gates should be positioned:

• Directly in front of unmanned loading bays when not in use
• At a height that stops vehicles but allows visibility for drivers
• With clear signage indicating when bays are open or closed

Pedestrian Segregation Near Bays

Loading bays attract foot traffic - people checking deliveries, managing paperwork, or directing drivers. Create dedicated pedestrian zones with barriers that separate walking routes from vehicle manoeuvring areas.

One of our clients, Altecnic (a leading UK supplier of heating and plumbing components), faced exactly this challenge when moving to their new warehouse. They installed polymer barriers, gates, and floor markings to create clear pedestrian routes near their loading zones, eliminating the confusion that often causes near-misses. Understanding how barriers can prevent common warehouse safety mistakes is crucial when planning these high-traffic zones.

Where Do Barriers Belong Around Doorways and Entrances?

Doorways and entrances are collision hotspots. Vehicles passing through have reduced visibility, and the door frames themselves are expensive to repair or replace.

Door Frame Protection

Install door frame protection on both sides of high-traffic doorways. These should extend at least 500mm beyond the door frame on each side to create a protective buffer.

For doorways frequently used by FLTs, consider full-frame protection systems that guard both the vertical jambs and overhead lintel. This is particularly important for:

• Cold store entrances
• Production area access points
• Goods-in/goods-out doorways
• Any doorway with restricted width or tight turning angles

Protruding Corner Protection

Corners near doorways are impact magnets. Bollards positioned at building corners guide traffic safely through tight spaces while protecting your building structure. They should be:

• Highly visible (bright polymer colour or reflective elements)
• Positioned far enough from the corner to be effective (typically 300-500mm)
• Tall enough to be seen by FLT operators (minimum 1100mm)

How Should You Position Barriers at Vehicle Crossing Points?

Crossings are where pedestrian routes intersect with vehicle traffic. Getting the barrier placement wrong here creates bottlenecks or forces people to take risky shortcuts.

Controlled Crossing Zones

Barriers should funnel pedestrians toward designated crossing points rather than allowing them to wander across vehicle routes anywhere. Think of it like creating a zebra crossing - you want clear start and end points.

Position barriers to:

• Define where pedestrians should wait before crossing
• Create clear sightlines for both pedestrians and drivers
• Prevent pedestrians from stepping directly into vehicle paths
• Guide people toward supervised or controlled crossings

Integration with Smart Systems

Modern crossings combine physical barriers with technology. LED projected floor markings can be activated when pedestrians need to cross, making the route instantly visible to FLT drivers.

What About High-Traffic Intersections and Corners?

Intersections and corners are where multiple traffic flows converge. Poor barrier placement here causes congestion, reduces visibility, and increases accident risk.

Maintain Clear Sightlines

Position barriers to protect people while preserving visibility. Barriers that create blind corners are dangerous - drivers can't see pedestrians stepping out, and pedestrians can't see approaching vehicles.

Consider Vehicle Turning Radii

FLTs need space to turn. Position barriers far enough from corners to allow comfortable manoeuvring without forcing drivers to make repeated corrections. Most counterbalance FLTs need at least 3 metres of aisle width for 90-degree turns.

Create Clear Priority Rules

Use barrier placement to establish who has priority at intersections. Barriers combined with LED projected crossings or traffic light systems remove ambiguity and keep everyone moving safely.

Get Your Barrier Placement Right From the Start

Barrier placement isn't about covering every metre of floor space. It's about protecting the zones where risk is highest and traffic patterns demand it.

Effective installations go beyond how your facility looks on paper to assess daily operations. That means observing real traffic patterns, identifying where people naturally walk, and understanding where FLTs frequently drift or take tight turns.

At Clarity, we don't just supply barriers. We start with a site assessment to map your risks and traffic flows. Then we design a barrier system that fits your operation, not the other way around.

Book a free site assessment and we'll show you exactly where barriers should go in your facility - and the reasons why.