Polymer Rack End Barrier - PAS 13 Tested Polymer Safety Barrier

The Polymer Rack End Barrier is a PAS 13 tested polymer safety barrier engineered to provide low-level impact protection for pallet racking systems within warehouse, logistics and industrial environments.

Designed as a flexible single rail end-of-aisle barrier, the system protects exposed pallet racking uprights and aisle ends from collisions caused by forklifts and other material handling equipment (MHE). The barrier deflects under impact and reforms to shape, helping reduce structural damage to racking, vehicles and floor infrastructure when compared with rigid steel protection systems.

Manufactured from flexible high-density polyethylene (HDPE) with mild steel base plates, the barrier combines durability with controlled deflection to provide reliable racking protection in busy warehouse operations.

Impact Performance and Testing

Brandsafe® single end-of-aisle barriers were independently impact tested in April 2023 to confirm performance and reliability in demanding warehouse environments.

Testing results demonstrated:

• 4.6 kJ impact absorption at 90°
• 9.2 kJ derived impact absorption at 45°
• 195 mm measured deflection
• Equivalent to a 3.7 mph impact from a 3,500 kg forklift
• All testing conducted on a concrete substrate

These results confirm the barrier’s suitability for environments exposed to repeated low-level MHE contact.

Material and Construction

• Manufactured from high-density polyethylene (HDPE)
• Mild steel base plates for structural fixing
• Flexible single rail bumper configuration
• Low-maintenance polymer construction
• Non-toxic and fade-resistant material
• Fully recyclable polymer

The HDPE formulation provides durability and resilience while maintaining high visibility and long-term performance in demanding operational environments.

The barrier is suitable for use in ambient, chilled and freezer environments, supporting deployment in food distribution facilities, cold storage warehouses and temperature-controlled logistics environments.

PAS 13 Compliance

The Polymer Rack End Barrier has been tested in accordance with PAS 13, supporting structured warehouse traffic management strategies and risk-based barrier selection.

The barrier provides a dedicated impact protection solution for pallet racking aisle ends, helping facilities reduce damage to storage infrastructure and improve operational safety.

Barrier Configuration and Dimensions

• Single rail polymer barrier configuration
• End-of-aisle protection design
• Barrier height: 468.5 mm
• Footplate width: 240 mm
• Available barrier lengths: 900 mm, 1100 mm and 2400 mm
• Surface mounted using Hilti HSA4 floor anchors
• Supplied with installation fixings

The compact low-level design allows protection of pallet racking without obstructing vehicle movement or reducing valuable warehouse floor space.

Visibility and Finish

Finished in high-visibility Safety Yellow and Grey, the barrier clearly defines protected racking areas and helps forklift and MHE operators identify aisle end protection zones.

Additional colour options may be available depending on project requirements.

The contrasting colour scheme improves visibility in busy warehouse environments and supports safer vehicle movement within storage areas.

Functional Benefits

• Protects pallet racking aisle ends from forklift impact
• Designed for warehouse racking protection
• Flexible HDPE construction absorbs and deflects impact energy
• Reduces damage to racking, vehicles and floors
• PAS 13 tested barrier system
• Compact low-level barrier profile
• Quick and easy installation with supplied fixings
• Suitable for ambient, chilled and freezer environments
• Fully recyclable and non-toxic material

Typical Applications

Commonly specified for:

• Warehouse pallet racking aisle ends
• Distribution centre storage areas
• Forklift operating zones
• End-of-aisle racking protection
• Industrial storage facilities
• Temperature-controlled logistics environments
• Food production and cold storage warehouses

The Polymer Rack End Barrier provides a reliable protection system for pallet racking infrastructure in environments where forklifts and other MHE operate within defined warehouse layouts.

Operational Integration

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

• Protection of exposed racking structures
• Reduction of pallet racking repair costs
• Clearly defined vehicle operating areas
• Controlled impact protection for storage infrastructure

The flexible HDPE construction allows controlled energy absorption while maintaining structural integrity and operational continuity following low-level impacts.

Performance Summary

The Polymer Rack End Barrier provides flexible polymer impact protection specifically designed for pallet racking aisle ends. Its PAS 13 tested performance, HDPE construction and controlled deflection characteristics deliver durable protection for racking systems in warehouse, logistics and industrial environments.