Warehouse and manufacturing facilities have one major issue in common. Forklifts and pedestrians have to share the same space every single day. Without proper protection, accidents can happen, and quickly.
Here’s the problem:
The Occupational Safety & Health Administration (OSHA) states that 70% of forklift accidents are preventable through the use of proper safety measures. That’s an incredibly large number of accidents when you consider the potential human and financial costs associated.
Luckily, there are tried-and-true solutions that do work. Barrier rails and guards provide an effective physical separation between moving equipment and everything else that is important.
Let’s take a look…
In This Guide
- What Are Barrier Rail Systems?
- Why Your Facility Needs Barrier Rails and Guards
- Types of Barrier Rail Systems
- Where To Install Barrier Rails
- How To Choose the Right System
What Are Barrier Rail Systems?
Barrier rail systems are heavy-duty protective systems that are designed to withstand impact from forklifts and other industrial vehicles. They can be thought of as the safety net for your facility.
Barrier rail systems provide a physical boundary between pedestrian walkways, machinery, storage racks and inventory, building columns and walls, work stations, and office areas.
When a forklift or other vehicle runs into a barrier rail, the rail is designed to absorb the impact and thus prevent damage to what is behind it. It’s a fairly simple concept.
But there is a caveat…
Not all barrier rails are created equal. The quality of your barrier rail system is directly related to how effectively it will protect your facility. For that reason, it’s well worth the investment in quality forklift barrier rails for any workplace safety plan. The right system provides your facility with the protection it needs to keep employees safe and operations running smoothly.
Why Your Facility Needs Barrier Rails and Guards
If you’re still not convinced barrier rails and guards are necessary, consider this. The National Safety Council reports that in 2023, there were 67 work-related deaths in the United States attributed to forklifts. These numbers don’t include the thousands of injuries that are not fatal.
Barrier rails and guards provide your facility with several critical safety benefits.
Protect Your Employees
This should go without saying, but your employees should always be the most important consideration in any workplace safety decision. Barrier rails create well-defined safe zones, where pedestrians can walk without having to be concerned about forklift traffic. Separation is key, especially in busy facilities where there is mixed traffic.
Prevent Equipment Damage
A forklift collision can result in thousands of dollars in damage. Machinery, storage racks, and inventory can all be affected. Barrier rails will absorb that impact before it has a chance to reach those valuable assets.
Reduce Downtime
Downtime can be the result of any accident. Time lost to investigations, repairs, and injuries all have the potential to disrupt operations. By installing barrier rails, many of these problems can be prevented before they occur.
Stay OSHA Compliant
OSHA requires employers to provide a safe and healthful workplace for their employees. Proper use of barrier rails helps show a commitment to workplace safety and can also help reduce the risk of fines associated with OSHA violations.
Types of Barrier Rail Systems
There are several different types of barrier rail systems from which to choose. Each type is suited for a specific application.
Single Rail Systems
Single rail barriers are the most basic form of protection. They are best suited for protection of equipment and rack systems. This type works well in areas with lighter traffic or where space is at a premium.
Double Rail Systems
Double rail systems are used for added protection in pedestrian areas. The dual-rail design creates a wider and more visible barrier and provides additional coverage against impact at different heights.
Steel Barrier Rails
Steel barrier rails are the more traditional option. They provide excellent strength and durability and do so at a competitive price point. Steel rails are generally rated to withstand impact from a 10,000-pound load traveling at 4 mph.
Polymer Barrier Rails
Polymer systems are a more modern option that are designed to flex when an impact occurs and then return to their original shape. This flexibility reduces floor damage and eliminates the need for constant repairs and replacement after collisions.
Lift-Out Rails
Lift-out barrier rail systems are those that can be temporarily removed to provide access when needed. They are useful in creating pedestrian pathways in areas that still need to be protected the rest of the time.
Where To Install Barrier Rails
Placement of barrier rails is everything. The following are some of the most critical areas when it comes to barrier rails.
Pedestrian Walkways
Any area where employees are walking around should be separated from forklift traffic. Barrier rails are the best way to create pedestrian pathways that are well-defined and designated on both sides.
Around Machinery
Expensive machinery needs to be protected at all costs. One collision is all it takes to potentially damage or destroy critical pieces of equipment and completely shut down production.
Storage Rack Areas
Storage racks that are loaded with inventory are prime candidates for forklift impact. Barrier rails are an effective way to help prevent the domino effect of forklifts running into racks.
Building Columns
Building columns are critical to the overall structural integrity of your building. For that reason, it’s important to protect them with either barrier rails or column guards.
Loading Dock Areas
Loading docks and other high-traffic areas see a lot of forklift activity. These areas will need robust protection as a result.
Office and Break Areas
Any office or break room that is located within the plant should be provided with barrier protection to separate them from the warehouse floor.
How To Choose the Right System
Selecting the right barrier rail system for your facility is dependent on your specific needs. Consider the following when making a decision.
Traffic Volume
Areas with high traffic levels should be provided with stronger protection. You might want to consider double rail systems or polymer barriers that can withstand repeated impacts.
Type of Equipment
Heavier equipment will require stronger barrier systems. Be sure that the rail system is rated to handle the weight and speeds of your particular forklifts.
Floor Conditions
The type of floor that your facility has will also impact the installation. Concrete floors work well for anchor-based systems, but other facilities may need alternative installation options.
Budgetary Constraints
Steel rails are less expensive to purchase upfront but will likely require more maintenance. Polymer systems are more expensive but often have lower overall costs due to decreased repair needs.
Future Expansion
Consider using modular systems that can be expanded as your facility grows. This will make it much easier to add on sections as your needs change in the future.
Wrapping Things Up
Barrier rails and guards are a crucial element of any facility that truly wants to prioritize workplace safety. These systems will protect your employees, your equipment, and your inventory from the everyday threat of forklift accidents.
As a quick recap, here are some key points to remember:
- Barrier rails provide an effective physical separation between hazards and people
- Multiple types of barriers are available for different applications
- Strategic placement can help maximize the protection
- Quality systems are a worthwhile investment when it comes to preventing accidents
When you take into account the loss of productivity, equipment damage, medical expenses, and potential OSHA fines, accidents cost facilities money at a rapid pace. Don’t wait for something to happen to you. Take some time to evaluate your facility’s traffic patterns and high-risk zones and then install the proper barrier rail system to keep everyone safe.
Your employees deserve it, and your bottom line will thank you for it.
