Understanding the challenge

Designing a solutions-led protection package for a high-volume fulfilment site.

As demand for rapid home delivery continues to accelerate, logistics companies are investing in ever larger fulfilment centres. A new distribution hub in the south-east of England was designed to handle thousands of orders per day. With multiple loading bays for heavy goods vehicles, high-bay racking, mezzanine floors and a large car park for staff and visitors, the facility presented a complex safety challenge.

The operator needed to protect people, assets and infrastructure without compromising operational efficiency or future growth. Brandsafe was appointed to deliver a comprehensive, solutions-led impact protection package.

Aligning products with risk zones

To ensure every risk was addressed with the appropriate level of protection, Brandsafe analysed the specific hazards within each area of the site and matched products accordingly. Rather than adopting a generic approach, we focused on the operational role each element would perform, ensuring every item specified had a clear purpose and measurable value.

The protection package included:

• MBT Heavy Duty Rail, a low-level steel rail designed to shield checker-plate walls, electrical boxes and low-level services from vehicle impacts.
• PolyWRAP column protectors, high-visibility sleeves fitted around I-beam columns to prevent structural damage and reduce repair costs.
• ImpactSAFE bollards, energy-absorbing bollards positioned at dock doors and around vulnerable services to guard against high-energy impacts.
• PVC car wheel stops, semi-flexible guides to define parking bays and prevent vehicle encroachment onto pedestrian walkways.
• Powder-coated Armco barriers with black ends and corners, robust guardrails used to segregate vehicle routes and remove sharp edges at termination points.
• Safety caging, modular mesh fencing systems used to secure valuable goods and sensitive equipment.
• HR50 handrails, modular pedestrian railings defining walkways and protecting critical pipework and storage zones.

Shielding walls and low-level services with MBT rails

Inside the warehouse, MBT Heavy Duty Rail was installed along checker-plate walls, housing switches, electrical boxes, and in front of exposed low-level pipework. Outside, the metal rail is used around external walls to protect against any low-level pallet impacts. Positioned at bumper height, the heavy-gauge steel rail intercepts forks and pallets before they can strike walls or services.

Its modular design adapts around corners, doorways and service cabinets, creating a continuous buffer that protects infrastructure without encroaching on valuable operational space.

Safeguarding I-beam columns with PolyWRAP protectors

The distribution hub relies on a network of structural I-beam uprights that are critical to its building integrity. Even a single forklift impact can bend or crack a column, resulting in costly repairs and operational disruption.

PolyWRAP column protectors were fitted around each I-beam, providing a high-density polymer buffer that absorbs and disperses impact energy. Their bright finish enhances driver visibility, while the stackable design covers base plates and fixings. In areas with tighter clearances or higher traffic frequency, additional skirts were installed to shield the lowest impact zones.

Defending dock doors and vulnerable services with ImpactSAFE bollards

Dock areas are among the most hazardous parts of any warehouse. Vehicles reverse frequently, forklifts shuttle between trailers and racking, and door frames must remain intact to maintain seals and security.

ImpactSAFE bollards were installed on either side of every loading bay door and around exposed services, including a water fountain and pipework. Working in conjunction with MBT rails, these bollards absorb high-energy impacts and protect critical utilities.

Each bollard incorporates an internal steel core with shock-absorbing materials and is secured using flush-mount anchors to minimise trip hazards. Replaceable polymer sleeves maintain appearance without the need for frequent repainting.

Organising the car park with PVC wheel stops

The site includes a large car park serving staff, visitors, delivery vans and electric vehicles. Polymer wheel stops were installed to ensure vehicles park accurately without encroaching onto pedestrian routes.

Low enough to avoid tyre damage yet durable enough to withstand repeated contact, these high-visibility stops assist drivers in judging distance and improve overall parking discipline, particularly in low-light conditions.

Separating vehicle routes with Armco barriers

Powder-coated yellow Armco barriers were deployed to protect key structures and manage vehicle movement. Around a raised pallet storage platform, the guardrails create a secure perimeter that prevents forklifts and tugs from dislodging stock.

Additional sections encircle a walk-in electrical enclosure, clearly segregating vehicle routes and establishing defined safety boundaries. Installed at a height that prevents HGV wheels from mounting kerbs, the bright finish improves visibility, while black polymer ends and corners remove sharp edges and improve termination safety.

Securing valuable goods with safety caging

Within the warehouse, certain areas hold high-value stock and automated equipment. To protect these assets, modular safety caging was installed to create secure rooms for storing valuable items. The fencing system uses steel posts and mesh panels that can be configured to form rooms or corridors, and gates with padlocks or digital locks restrict entry to authorised personnel.

The mesh allows supervisors to see inside the caged area while maintaining airflow, and its reconfigurable design means cages can be extended or adapted as inventory profiles change.

Guiding pedestrians and protecting utilities with HR50 handrails

Pedestrian safety is paramount in high-traffic environments. HR50 handrails provide durable separation between walkways and machinery while protecting critical pipework and storage areas.

Constructed with galvanised steel uprights and bright polymer sleeves, the system is highly visible and built to last. Handrails were installed along main walkways, around pipework, at mezzanine edges and on stairways leading to offices and welfare facilities. Self-closing gates were fitted at crossing points to provide controlled pedestrian access.

Delivering results, safety and efficiency

Brandsafe's targeted approach delivered measurable benefits:

• Enhanced safety: clear segregation significantly reduced collision risk. Energy-absorbing systems protected building fabric and utilities, while column protection preserved structural integrity.
• Operational efficiency: defined traffic routes improved site flow, enabling staff and drivers to operate with greater confidence and fewer interruptions.
• Durability and low maintenance: galvanised steel and high-density polymers resist corrosion and wear. Replaceable components reduce lifecycle costs and maintain appearance.
• Scalability: the modular nature of the systems allows for extension or reconfiguration as operations expand or layouts evolve.

Aligning protection with operational risk

"This project demonstrates the importance of aligning protection systems with operational risk rather than simply selecting products. By assessing each zone individually, we were able to deliver a balanced package of polymer and steel solutions that protect people, infrastructure and productivity without compromising future flexibility." George Howe, Head of Commercial Sales.

A safer, more adaptable facility

By matching safety solutions precisely to each risk zone, Brandsafe delivered an efficient and purpose-built impact protection package for a modern distribution hub. Every element was selected with intent, ensuring nothing was over-specified or under-engineered.

The result is a safer, more efficient and adaptable facility that supports the client's long-term growth ambitions.

Partner with Brandsafe

As part of IWS Group, Brandsafe combines innovation, customer service and quality across every project we deliver.

Planning an industrial refurbishment, site expansion or new-build? Brandsafe supports specifiers and operators with high-visibility, durable safety systems that protect people, infrastructure and operations at every stage.

Browse our product pages to explore our full range of sustainable safety solutions, tailored to the demands of your site. For insights into best practices and real-world applications, visit our blog or explore our detailed case studies.

Ready to improve safety on your next project? Contact our team today to see how Brandsafe can help you create a safer, more efficient operational environment.

End Client: NewCold

Architect: Ashton Smith Associates Ltd

Main Contractor: TSL Ltd

This project showcases how impact protection can be effectively implemented throughout cold storage facilities, playing a vital role in maintaining safety, efficiency, and long-term performance. NewCold, Dinteloord is a fully automated high-bay cold storage facility in the Netherlands with an overall building footprint of 142 x 122 metres. Situated on a 60,000 square metre plot of land in the Municipality of Steenbergen, this site is ideally located to access the major Rotterdam-Antwerp-Brussels transport corridor.

This grid-independent cold storage warehouse has a capacity of 134,000 pallet locations, which can be positioned at heights of up to 40 metres. As a busy food storage warehouse, temperatures can reach as low as -23oC, and the building has 25 Loading Bays to keep these products moving swiftly.

Given the size and specialist nature of this storage facility, a range of bespoke impact protection solutions have been installed by Brandsafe to help this site operate in a safe and efficient manner. Brandsafe were appointed by Main Contractor, TSL Ltd, to provide various impact safety systems in and around this new purpose-built facility.

Food-Safe Polymer Barriers: Effective Impact Protection in Cold Storage Facilities

The project architect, Ashton Smith Associates Ltd, specified a requirement for over 90 linear metres of Polymer Safety Barriers throughout this building. Brandsafe’s Double Bumper Barriers were selected for this task, as they are suitable for use in ambient, chilled, and freezer environments.

These safety barrier systems have also been independently tested by TÜV Nord to PAS 13 standards, and are able to withstand impacts of 14,200J. In real-world terms, that’s a head-on impact from a 3,500kg forklift truck travelling at 6.4mph.

Another major benefit to these Polymer Safety Barriers is that they are non-toxic and therefore suitable for use in food storage environments. This along with their impact resistance was an important factor in their selection for this NewCold site.

Door Protection Duty

With 25 active Loading Bays at this site, there’s numerous busy doorways in and out of the building that are particularly at risk of damage from accidental impacts. Fortunately, this potential risk has been recognised here, and Brandsafe’s ImpactSAFE Bollards have been deployed to provide the required protection.

Brandsafe’s on-site teams diligently installed 110 of these bollards in pairs to protect the busiest internal and external doorways in use throughout the building. Each of these PAS 13 certified bollards is 1300mm high, and they were specified with bright yellow cover kits to maximise their visibility to pedestrians and vehicle operators.

Continuing on the theme of Building Protection, a number of Brandsafe’s PolyWRAPs were installed to protect key structural columns around this site. Secured in place with sturdy ratchet straps, these Column Protectors were also equipped with Forklift Impact Skirts for an extra layer of low-level protection.

Access All Areas

Brandsafe works on numerous buildings of this type, and External Access Ramps are often areas that require high levels of impact protection. This project was no different, with Armco 760 Safety Barriers installed along the full length of this 20+ metre ramp.

Both the standard Armco 760 and the Armco 760HR safety barrier variants were utilised for this project. Standard Armco 760 was installed alongside the external wall of the building, with the Armco 760HR variant used to create a safe pedestrian walkway.

Brandsafe’s handrail systems offer a smooth, snag-free finish, with the ergonomic design of the polymer sleeving providing a warm-to-touch surface for pedestrians.

We fitted these Armco Barriers with Armco Safety Ends and Armco Post Caps to ensure that personnel using the site are protected from sharp edge injuries, as well as offering additional visibility for vehicle operators.

Car Park Safety

Armco 760 Safety Barriers were also put to good use in the Car Park, with both bolt down and potted variations installed here. Over 70 linear metres of these safety barriers were deployed in the areas with the highest risk of vehicle impacts.

There was also a requirement at this site for 50 of our HGV Wheel Stops. Made from recycled rubber, these 150mm high wheel stops have built-in hi-vis strips for an additional level of pedestrian and driver visibility.

The combination of these impact protection systems provide effective protection for pedestrians moving around a potentially busy car park, as well as keeping vehicles and other valuable assets damage free.

Complementary Safety Products Featured in This Project

• Our very own Brandsafe-manufactured Yellow Polymer Bollards
• Powder-Coated Yellow Pit Steel Guardrail
• Low-Level Double-Stacked Yellow Powder-Coated Steel Guardrail
• Armco Accessories, including Armco safety ends with diamond-style reflectors
• Secure Caging preventing entry and tampering with the mains power supply
• Metal Hoop Guards providing protection for light posts

Each of these unique systems has played a vital role in strengthening the overall safety and functionality of the warehouse. The Brandsafe-manufactured Yellow Polymer Bollards provide superior impact absorption and high visibility around vulnerable structures. Brandsafe’s experience with impact protection in cold storage facilities ensures that every installation meets the demanding conditions of low-temperature environments. While the Powder-Coated Steel Guardrails offer robust, long-term protection in high-traffic areas. Armco Accessories with diamond-style reflectors enhance visibility and awareness, particularly in low-light zones. The Secure Caging prevents unauthorised access to critical equipment, and the Metal Hoop Guards shield light posts from accidental impact. Together, these enhancements have proven critical in safeguarding key points across the site, ensuring a safer, more efficient operational environment.

The Final Details

With NewCold’s people, property, and processes now protected, we were now in the position to add the finishing touches prior to handover. A number of Potted Lamp Post and Corner Protectors were installed, providing robust and cost-effective protection in these busy areas on-site.

To complete this project, Brandsafe also fitted two Cycle Shelters and a Smoking Shelter to offer useful amenities for the end client and their staff. This 9200mm long run of shelters included a number of hoop cycle racks and a seating bench to maximise comfort and convenience for employees.

George Howe, Head of Commercial Sales at Brandsafe, commented:

“We’re proud to have delivered another successful project in partnership with TSL Ltd at NewCold, Dinteloord. This cold storage facility presented a unique challenge, requiring bespoke impact protection systems capable of performing in extreme low-temperature environments.

Our installation included a wide range of polymer and steel safety solutions, each tailored to the specific operational needs of the site. From PAS 13-tested polymer barriers to Armco systems and custom guardrails, every element was designed to protect people, property, and processes.

A huge thank you goes to our on-site Project Delivery Teams, whose expertise and attention to detail ensured this complex installation was completed safely, efficiently, and to the highest standard. Their hard work continues to set the benchmark for excellence in industrial safety.”

With urban logistics space at a premium, this Amazon distribution centre in Bracknell is a crucial hub for last-mile deliveries in the region.

Brandsafe were tasked with preparing this unit to function as safely as possible at its optimum operating capacity.

Project Overview

End Client: Amazon UK

Developer: SEGRO plc

Main Contractor: TSL Ltd

Architect: SMR Architects Ltd

Last-mile Delivery Centres are fast becoming a common fixture for businesses such as Amazon, especially when they are looking to service densely populated areas from one central logistics location.

These types of buildings are always busy, with a number of commercial vehicles operating in and around the warehouse at any given time.

As such, accidental impacts are always a potential risk, but this is a risk that can be mitigated by the correct application of impact protection systems.

The Brandsafe Service

Brandsafe were appointed by Main Contractors TSL to supply and install a wide range of traffic and pedestrian safety products at this site.

Managing the flow of vehicles around such a busy operational location takes careful and considered planning.

Brandsafe is adept at designing and advising on product layouts, utilising our experience to provide a solution tailored to the requirements of the end client, while remaining within the required project budgets and timescales.

Industrial Safety Barriers

Key to the installation that Brandsafe provided at this site are the bespoke runs of Armco Safety Barriers, situated both internally and externally.

Internally, the busy traffic lanes and ramps of the site's multi-storey car park are flanked by these safety barriers, with highly visible Armco Barrier Accessories installed to prevent any accidental impacts.

Fishtail Safety Ends have been used to great effect here, as their shape naturally deflects vehicles away to safety without causing any damage.

Car Park Safety

Outside, in the external car park, custom yellow powder-coated Armco Barriers were installed to protect the perimeter and any entry / exit gates.

These yellow safety barriers were also installed at key intervals inside the building as well, in areas where extra visibility levels were deemed to be necessary for ensuring safe operation.

With the car park naturally being a hive of activity, numerous commercial Speed Bumps and Wheel Stops were added to restrict vehicle speeds and roll aways in the area.

Column Protection

A number of internal and external structural columns across this site were deemed to be at risk of vehicular impacts, which is why we took steps to protect them.

The Brandsafe PolyWRAP Column Protector range was specified to provide robust, flexible and highly visible protection for these columns. With its ability to fit a number of different column widths as standard, it was easy for our site teams to roll this impact protection solution out for Amazon.

Pedestrian Safety

As always, the safe movement of people around the building is our top priority. In this instance, the pedestrian routes are clearly marked by handrail, either installed as a standalone Pedestrian Handrail (HR50) system, or attached to an Armco Barrier.

Modular Security Caging was installed inside the building to allow safe and secure access to key operational assets for the approved personnel. Whereas outside the building, Cycle and Smoking Shelters were installed to protect staff and their possessions from the elements.

The Finishing Touches

With the building now operational, Brandsafe were tasked with protecting busy and potentially vulnerable doorways and loading bays. This was done through a strategic combination of ImpactSAFE Heavy Duty Bollards and ImpactSAFE Protection Posts.

With their strong steel cores and attention-grabbing polymer covers, these systems are the ideal fit for this purpose. Product selection was then made based on the types of vehicle(s) operating in the area (HGVs and/or forklifts), and the overall space available.

Contact us today to see how we can help with your impact protection requirements.

Brandsafe - Safety, Simplified.

Clipper Group provides warehousing, distribution and logistics for multiple retail and high value brands. Providing services for many brands – large and small – across the UK, it is essential their operations perform with speed and accuracy, whilst providing protection and security to the people and the goods that pass through their doors.

Challenge:

To create a system that enables the workforce to navigate through the building safely, securely and efficiently. We had to provide a solution that fulfilled the security requirement, to protect the high value goods that are on site. We had to ensure pedestrian safety, without disturbing the vehicle traffic and operations.

Solution:

The first thing we looked at was identifying where there could be ‘natural’ break points in the pedestrian routes for traffic to pass through safely, to keep all traffic moving – pedestrians and vehicles.

From doing this, we implemented a bespoke system for Clipper, which included:

• A secure cage walkway – a mesh, walkway system that filtered staff from point A to point B (security check).
• Barriers to keep the pedestrian routes safe from the trucking routes.
• Integrated natural break points, with pedestrian gates, for traffic to pass safely through without interrupting pedestrian traffic flow.

The result:

In place at Clipper, we now have a high quality, sustainable and highly visible safety traffic solution, which ultimately keeps pedestrians safe. With the added security measures, it also ensures that the relevant security system and processes are in place to protect their valuable goods.