Is a W Beam Really the Best Barrier Option for My Workplace?

ForkSafe Barrier (Toll)

When exploring barrier options for workplaces, clients often ask if they can use the same W Beam barriers used on roads, in car parks, or outside facilities as they use in their warehouses, logistics centres, or plants.

They can be used in workplaces. However, the real question is, should they be? The answer is no, not if you want a forklift impact-rated barrier system that gives you the maximum amount of operational space.

Installing any old steel barrier without considering the unique needs of your workplace can result in wasted space and costly accidents that could have been prevented.

In this article, we’ll cover:

  • Why Not All Barriers Are the Same
  • Where W Beam Barriers Work Best
  • ForkSafe vs W Beam Barriers: Key Differences (comparison table)
  • Which Barrier Is Right for My Site?

Why Not All Barriers Are the Same

It’s essential to recognise that not every barrier is designed for the same purpose. A forklift barrier that protects staff in a warehouse faces very different demands than a roadside barrier that needs to stop a vehicle at speed.

Materials, design, and installation all change depending on what you’re trying to achieve, whether that’s managing pedestrian flow, protecting assets, or preventing serious collisions. The challenge comes when the wrong barrier is chosen for the wrong environment, which can create a false sense of security or even introduce new risks.

The question you should be asking yourself is not “Do we need a barrier?” but “What do we need this barrier to actually do?”. Being clear on that upfront helps you select the right type of barrier that does the job you’re counting on it for.

Where W Beam Barriers Work Best

A W Beam barrier is a heavy-duty steel barrier commonly used on roads or motorways where vehicles are travelling at speed, in carparks where heavy vehicles move through, and outside facilities where trucks are likely to be coming in and out of the area.

TruckSafe Barrier

The Limits of W Beam Barriers in Workplaces

While W Beam barriers can be used in workplaces as a safety barrier, there are some key factors to consider when installing them in an area such as a warehouse or logistics centre.

W Beam Barrier Considerations:

  • Bulky design: These barriers are up to 300mm in width and can take up unnecessary operational space due to their size.
  • Impact testing: Armco is impact tested in compliance with the AS/NZS 1170.1, which is based on the physical impact of cars and other vehicles, not forklifts and other materials handling equipment (MHE).

The lack of impact testing against forklifts and other MHE makes the W Beam barrier unsuitable for workplaces, while the clunky design can take up valuable space.

ForkSafe Barriers: Save Operational Space and Reduce Maintenance Costs

ForkSafe™ Steel Barriers are a certified, modular steel barrier system designed to protect buildings, assets, and pedestrians from damage or injury caused by forklifts and other MHE. Due to its modular design, this barrier system is highly customisable, easy to install, and ideal for ongoing maintenance.

  • Space-saving: ForkSafe barriers have a width of 90mm, which reduces the amount of operational space they occupy.
  • Modular and easily modifiable: The highly customisable to meet your site-specific requirements
  • Crumple Zone Technology (CZT): designed to absorb impact, reduce shock to forklifts or MHE, and protect your concrete floor from blowing out.
  • PAS 13 Impact Tested: PAS13 is a testing method specifically designed to measure barrier strength and durability against forklift and other MHE impact in industrial environments — not just vehicles.


Related Article: “PAS 13 Steel Barrier Testing: What It Is and Why It Matters.”

ForkSafe vs W Beam Barriers: Key Differences

Identifying the differences between ForkSafe and W Beam Barriers will help you make an informed decision about which barrier is right for your site. We’ve put together a handy comparison table to show you the key differences at a glance.

W Beam vs ForkSafe Table
W Beam vs ForkSafe Table


Related Article: “The ForkSafe Barrier Range: A Comprehensive Overview.”

Which Barrier Is Right for My Site?

Deciding which barrier is right for your site depends on your specific situation and the objectives you’re trying to achieve. Before investing in a steel barrier, consider:

  • What environment you’re installing into, e.g, a warehouse, carpark, plant, or road
  • The types of vehicles travelling through the area, e.g trucks, cars, or forklifts
  • The size of the space as a whole
  • The volume of traffic moving through the area
  • Where and when vehicles intersect with pedestrians

The safest barrier for your workplace isn’t decided by what’s most common, but by what your site actually needs. A warehouse with constant forklift traffic faces very different risks than a car park or state highway.

Before installing any barrier, step back and ask yourself the questions above. By matching the barrier to your environment — whether that’s Armco, ForkSafe, or another option — you avoid wasted spending, protect your people, and ensure the solution genuinely does the job you expect it to.

If you’re still unsure what safety barrier is right for your workplace or site, we’re here to help. We can discuss your situation and provide advice on the range of steel barrier options available to you. Get in touch with our team today!


Related Article: “How Much Do Steel Barriers Cost and Why Should I Invest?”

How Flexible Barriers Helped Lineage Safeguard Their Cold Storage Facility

d-flexx mono plus barrier

From a single site to becoming the world’s largest temperature-controlled warehousing and logistics company, Lineage partners with food and beverage companies to help make the cold chain more efficient, sustainable, and reliable, all while feeding the world and eliminating food waste.

Lineage recently completed a large-scale project to upgrade their Traffic Management Controls across multiple sites in New Zealand. With a focus on improving safety, they needed a partner that could guide them through the process of separating people and MHE (material handling equipment), as well as protecting expensive and valuable assets.

We were privileged to work with Lineage on finding the right pedestrian and traffic safety solutions for their sites. Since the project’s completion, we caught up with North Island Health and Safety Manager Ange Blom to get her insights on how it all went.

Q. What was the catalyst for needing to carry out this safety improvement?

A. We have a number of areas in the business with pedestrian and forklift interaction due to the design of the building and how work has changed.

Q. What considerations were on your mind when you were looking for a solution?

A. People/MHE separation, barriers that could handle being struck by MHE in occasional circumstances, a visual cue for people to follow and availability of replacement parts should the need arise.

Q. Why did you choose Vanguard?

A. Industry knowledge and a good reputation. We had previously purchased from Vanguard, and it’s great that they can supply nationwide.

Q. What was your experience of investigating and implementing the Vanguard solution?

A. We contacted Vanguard, and a representative came to site to view our risk areas and provide advice on the right solution. The team were very flexible when it came to making changes and staging the project over multiple phases of improvement.

Q. How has the Vanguard solution changed how people behave on your site?

A. The flexible barriers provide safe passage for workers who previously commuted through live lanes of operation. We’ve been able to reduce that across much of the site, and our workers felt consulted and valued throughout the design and post-implementation process.

Q. What benefits has Lineage experienced thus far from implementing these improvements?

A. Reduced risk of people vs MHE interaction, safe passage for visitors and contractors to view our operation, standardisation across the sites for traffic management.

Q. Do you have any advice for someone in your position facing a similar situation?

A. If possible, get in touch with sites that have implemented similar solutions to learn about what worked and what didn’t. Contact Vanguard to get expert knowledge and a site appraisal.

Q. Is there anything else you’d like to share?

A. Appreciated your team’s swift and regular follow-up and patience as we got organised—good communication across the project. I appreciated having the photos of our site with the product overlaid, which gave me a visual idea of the product installed. The installers were responsive and easy to deal with. Our learning was that we needed to consider certain aspects, such as gates and electrical cabinets being able to open once the barriers are in place.

d-flexx mono plus barrier

d-flexx Mono Plus Barrier

 

 

 

 

 

 

Cage Barrier

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Need help upgrading traffic management controls and safety in your workplace? Give us a call or fill out the form below so we can gain a better understanding of your situation and recommend the right solutions for your site.