Warehouse Safety Barriers and Pedestrian Segregation: An HSE Compliance Guide

The Legal Requirement for Pedestrian and Vehicle Segregation

Workplace (Health, Safety and Welfare) Regulations 1992 Regulation 17 requires that traffic routes be suitable for the persons and vehicles using them, that they be sufficient in number, suitably positioned and of sufficient size. The core principle is straightforward: wherever it is reasonably practicable, pedestrians and moving vehicles should travel on separate routes. Where shared routes are unavoidable, the risks must be controlled through markings, signage, speed limits, and physical measures.

HSG136 Workplace Transport Safety, published by the Health and Safety Executive (HSE), provides detailed guidance on implementing these requirements. A formal traffic management plan — covering how vehicles and pedestrians move through the site — is expected of any business operating vehicles on their premises.

Why Segregation Matters

Workplace transport incidents involving pedestrians being struck by vehicles account for a significant number of fatal and life-changing injuries in UK workplaces each year. Warehouses, distribution centres, and manufacturing sites are among the highest-risk environments. The proximity of forklifts operating at speed — often with restricted sightlines due to loads — and pedestrians moving between workstations creates conditions where even brief lapses in segregation can prove catastrophic.

Physical barriers are the most reliable control because they do not depend on behaviour: they prevent vehicles and pedestrians from occupying the same space, regardless of distraction, habit, or poor visibility.

Types of Safety Barrier

Steel Armco Barriers

Armco-style corrugated steel barriers are commonly used to protect columns, racking uprights, walls, and pedestrian zones from vehicle impacts. Their corrugated profile is engineered to absorb and deflect energy, which reduces structural damage to the building and redirects errant vehicles rather than stopping them abruptly. They are typically finished in yellow for high visibility and bolt directly to the floor.

Bolt-Down Post-and-Rail Systems

Post-and-rail barriers use upright steel posts set into floor flanges, connected by horizontal rails to create a continuous barrier line. These are highly versatile — suitable for creating pedestrian walkways, machine guards, and perimeter protection. Heights vary by application: pedestrian barriers are typically 1,000–1,200mm to be clearly visible and act as a physical deterrent; vehicle-side barriers require a minimum of 600mm to provide meaningful impact resistance.

Flexible Polymer Barriers

Polymer or polyethylene barriers are increasingly popular in environments where vehicle impacts are frequent. Unlike steel barriers, polymer barriers flex on impact and return to shape, protecting both the vehicle and the barrier system from damage. They require less maintenance after minor impacts and are particularly well-suited to busy loading bays and high-throughput warehouses.

Key Clamp Systems

Key clamp fittings offer a highly adaptable solution for constructing custom barriers, handrails, and guard rails without welding. The system uses galvanised steel tube and cast iron or malleable iron fittings tightened with a grub screw — no specialist equipment needed on site. This makes key clamp ideal for situations where standard barrier dimensions do not suit the layout, or where barriers need to be reconfigured as the warehouse changes. Galvanised steel provides excellent corrosion resistance for both indoor and outdoor use.

Visibility and Marking Requirements

HSG136 emphasises that segregation must be visible and consistently maintained. Key requirements include:

• Yellow and black markings: Floor markings should clearly delineate pedestrian zones and vehicle lanes. Paint or floor tape in yellow or yellow and black chevrons are standard.
• Convex mirrors at blind corners: Every blind corner, blind junction, and concealed exit should have a convex safety mirror of appropriate diameter to give drivers and pedestrians advance awareness of approaching traffic.
• Adequate lighting: Poor lighting is a major contributing factor in warehouse incidents. All traffic routes, pedestrian walkways, and crossing points should be well lit at all times the site is in use.
• Speed limit signs: Internal speed limits (typically 5mph or 10mph) should be posted at site entrances and repeated at intervals. The limit must be appropriate to the layout and the mix of pedestrians and vehicles.

Pedestrian Crossings and Designated Walkways

Where pedestrians need to cross a vehicle route, designated crossing points should be established. These should be clearly marked with floor markings and, ideally, signs at pedestrian height. In high-traffic areas, physical controls such as barriers that channel pedestrians to the crossing point — preventing them from crossing elsewhere — significantly reduce risk.

Designated pedestrian walkways should be physically separated from vehicle routes wherever the layout allows. Where barriers create a walkway, the route should be continuous, without gaps that encourage pedestrians to cut across vehicle lanes.

Developing a Traffic Management Plan

HSG136 sets out the elements of a traffic management plan. At a minimum, this should cover:

1. A site plan showing all vehicle routes, pedestrian routes, crossing points, speed limits, and one-way systems
2. The types of vehicles operating and their permitted areas
3. Rules for visitors and contractors on site
4. Emergency procedures if a vehicle incident occurs
5. Inspection and maintenance arrangements for barriers, markings, and mirrors

The plan should be reviewed whenever the site layout changes significantly and at least annually.

Inspection and Maintenance

Barriers that have sustained impact damage should be inspected and replaced if their protective capacity has been compromised. A dented Armco barrier or a bent post-and-rail system may still look functional but could fail to provide adequate protection in a subsequent incident. Regular visual inspections — ideally as part of daily site checks — ensure damage is identified and acted on promptly.

Browse our range of warehouse safety equipment, including barriers, floor markings, and pedestrian protection, and our key clamp fittings for bespoke barrier and handrail construction.