Description
Protecting racking ends where impact is most likely
The end of a racking aisle is one of the highest-risk locations in any warehouse. Forklifts and pallet trucks turning into and out of aisles create repeated impact risk at the racking end, and each unaddressed collision adds cumulative damage to the upright and surrounding infrastructure. That risk is predictable. Addressing it before damage occurs is the purpose of the Rack End Barrier.
The Rack End Barrier sits at the aisle end, absorbing and deflecting impacts before they reach the racking. Manufactured from flexible HDPE with mild steel base plates, the barrier deflects on contact and reforms its shape after impact. This means the barrier continues to provide protection after a collision without requiring immediate replacement. Minimal force transfers into the floor on impact. This reduces floor damage and keeps repair costs low over the lifetime of the installation.
Independently tested performance
Brandsafe® Rack End Barriers have been impact tested by IWS Group, to ensure superior performance and reliability. At a 90° impact angle the barrier absorbed 4,600J of energy with a measured deflection of 195mm. At a 45° impact angle it absorbed 9,200J. These results are equivalent to a 3.7 mph impact from a 3,500 kg forklift. All testing was conducted using M12 Safety Plus Anchors, confirming performance under standard warehouse conditions.
The data speaks for itself. For sites undergoing risk assessments, safety audits or insurance reviews, this provides documented evidence of barrier performance rather than a general specification claim.
Construction and material properties
The barrier is manufactured from flexible high density polyethylene with mild steel base plates. The HDPE deflects impact on contact and reforms to shape, reducing damage to floors, vehicles and infrastructure compared with rigid steel alternatives. The material is impervious to moisture, mould, corrosion, acid, alkaline and most solvents, requiring no repainting or ongoing maintenance beyond routine visual inspection.
Both materials are non-toxic and fully recyclable. The barrier is suitable for use in food production facilities, cold storage and freezer environments across the full ambient to freezer temperature range.
Visibility, sizing and installation
The Rack End Barrier is supplied in Safety Yellow and Grey as standard, providing clear visual demarcation of aisle ends for MHE drivers and warehouse teams. High visibility at the point of highest risk supports safer vehicle movement throughout the site.
Standard lengths are 900mm, 1100mm and 2400mm, covering the majority of standard racking aisle configurations. The barrier stands at 468.5mm high with a 240mm footplate width. Each baseplate fixes using M12 x 120mm Safety Plus Anchors, with all fixings supplied. Installation is straightforward and keeps operational downtime to a minimum. Bespoke colours are available on request.
Supporting compliance and duty of care
Under the Health and Safety at Work Act 1974 and the Workplace (Health, Safety and Welfare) Regulations 1992, employers are required to keep vehicle and pedestrian routes safe and to mitigate foreseeable risks at known impact points. Racking ends are among the most consistently identified hazard locations in warehouse safety inspections.
The Rack End Barrier provides a documented physical control measure at the aisle end with independently verified impact performance data to support it. For H&S managers, facilities teams and specifiers, this combination of physical protection and test evidence strengthens the overall safety case for the site. For businesses subject to insurance reviews or third-party audits, having independently tested barrier systems in place at racking ends demonstrates a proactive and evidenced approach to impact risk management. The result is fewer inspection findings, lower repair costs and a stronger safety record across the site.
