Double Bumper Safety Barrier - PAS 13 Tested Polymer Safety Barrier

The Double Bumper Safety Barrier is a PAS 13 tested polymer safety barrier engineered to provide heavy-duty, low-level impact protection in warehouse, logistics and industrial environments where forklifts and other material handling equipment (MHE) operate.

Manufactured from high-density polyethylene (HDPE) with mild steel base plates, the dual rail configuration increases impact absorption capacity while maintaining controlled flexibility. The barrier is designed to deflect under impact and return to shape, helping reduce structural damage to floors, anchor points, vehicles and building infrastructure when compared with rigid steel barrier systems.

The system is intended for use within warehouse traffic management layouts where vehicle routes, machinery and infrastructure require protection from repeated contact with forklifts, counterbalance trucks, reach trucks and other heavy pallet handling equipment.

The flexible polymer construction allows the barrier to absorb and disperse impact energy while maintaining structural integrity, helping protect operational environments exposed to regular vehicle movement.

Impact Performance and Testing

The Double Bumper Safety Barrier has been independently tested and certified by TÜV Nord in accordance with the PAS 13 global code of practice for industrial safety barriers.

Testing results demonstrated:

• 14.2 kJ impact absorption at 90°
• 214 mm measured deflection
• Equivalent to a 3,500 kg forklift travelling at 6.4 mph
• All testing conducted on a concrete substrate

A derived impact absorption value of 28.4 kJ at 45° can be extrapolated from the verified 90° test performance, providing an indication of performance under angled vehicle contact.

These results confirm the barrier’s suitability for environments exposed to higher energy impacts and repeated contact from material handling equipment.

When designing protection layouts, the measured deflection distance should be considered to ensure sufficient clearance between the barrier and protected infrastructure.

Material and Construction

The Double Bumper Safety Barrier is manufactured from high-density polyethylene (HDPE) combined with structural mild steel base plates.

Material characteristics include:

• Manufactured from high-density polyethylene (HDPE)
• Structural mild steel base plates
• Flexible dual bumper rail configuration
• Low maintenance polymer surface finish
• Non-toxic and fade-resistant material
• Fully recyclable polymer construction

The HDPE formulation provides durability and resilience while maintaining high visibility within operational environments. The polymer structure allows controlled deflection during impact events, helping reduce damage to floor fixings and structural elements.

The barrier is suitable for installation in ambient, chilled and freezer environments, making it appropriate for use in food distribution, cold storage and temperature-controlled facilities.

PAS 13 Compliance

The Double Bumper Safety Barrier has been tested in accordance with PAS 13 and independently verified by TÜV Nord.

Its performance characteristics support structured warehouse traffic management strategies where safety barriers are selected according to vehicle risk, operating speeds and impact exposure.

The barrier is suitable for installation within documented vehicle traffic management systems where controlled impact resistance is required to protect operational infrastructure.

Barrier Configuration and Dimensions

The barrier system is designed using a dual rail bumper configuration to increase impact resilience in areas exposed to heavier MHE and higher vehicle traffic.

Standard configuration includes:

• Double bumper rail design
• Standard barrier height: 670 mm
• Footplate width: 300 mm
• Centre post incorporated for runs of 3 metres or greater
• Surface mounted installation using Hilti HSA4 floor anchors
• Supplied with installation fixings

The dual rail configuration increases protection in environments exposed to higher impact energy, particularly at turning points, vehicle circulation corridors and high-traffic operational zones.

Visibility and Finish

The Double Bumper Safety Barrier is supplied in Safety Yellow and Grey as standard.

This high-visibility colour configuration improves barrier recognition for forklift and MHE operators and supports the clear visual demarcation of protected areas within warehouse and industrial environments.

Bespoke colour options may be available on request, subject to minimum order quantities.

Functional Benefits

• Heavy-duty low-level impact protection
• Designed for environments operating larger forklifts and MHE
• Dual bumper configuration increases impact resilience
• Controlled deflection reduces floor and anchor damage
• Independently PAS 13 tested and verified by TÜV Nord
• Helps protect machinery, racking and infrastructure from vehicle impact
• Suitable for ambient, chilled and freezer environments
• Low maintenance polymer construction
• Fully recyclable and non-toxic material
• High visibility colour improves hazard awareness

Typical Applications

The Double Bumper Safety Barrier is commonly specified in warehouse and industrial environments where infrastructure requires protection from vehicle movement.

Typical applications include:

• Protection of racking aisles and storage systems
• Rack end protection at aisle ends
• Machinery and equipment protection zones
• Warehouse vehicle circulation routes
• Loading bay traffic routes
• Distribution centre marshalling areas
• Cross-docking zones
• Industrial processing environments
• Temperature-controlled logistics facilities

The barrier can also be used as rack end protection, helping shield pallet racking from forklift contact in aisle end positions.

Operational Integration

Within PAS 13 aligned traffic management systems, the barrier supports:

• Protection of infrastructure within vehicle operating zones
• Risk-based barrier placement within warehouse layouts
• Impact protection for racking, machinery and structural elements
• Clearly defined protected areas within operational environments
• Hazard visibility for forklift and vehicle operators

The flexible HDPE construction allows the barrier to absorb and dissipate energy from low-level impacts while maintaining operational continuity following contact.

Summary

The Double Bumper Safety Barrier provides heavy-duty polymer impact protection for warehouse and industrial environments where larger material handling equipment operates. Its PAS 13 tested performance, dual rail configuration and controlled deflection characteristics deliver a durable protection system designed to protect machinery, racking and infrastructure from vehicle impact in demanding operational environments.