September 10, 2025 - Vanguard Group NZ

Should you use W-beam barriers in your warehouse?

When exploring barrier options for workplaces, clients often ask whether they can use the same W-beam barriers (often called Armco) that are used on roads, in car parks or outside facilities in their warehouses, logistics centres or plants.

W-beam barriers 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 aren’t all safety barriers the same?
Where do W-beam barriers work best?
ForkSafe vs W-beam barriers: key differences (comparison table)
Which barrier is right for my site?

Why aren’t all safety barriers 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 from 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 environment. That can create a false sense of security or even introduce new risks.

The question to ask 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 for the job you’re counting on it to do.

Where do W-beam barriers work best?

A W-beam barrier is a heavy-duty steel barrier commonly used:

on roads or motorways where vehicles travel at speed
in car parks where heavy vehicles move through
outside facilities where trucks are likely to come in and out of the area.

What are the limits of W-beam barriers in workplaces?

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

W-beam barrier considerations:

Bulky design: These barriers are up to 300mm wide and can take up unnecessary operational space because of their size.
Impact testing: W-beam barriers are designed for vehicle impacts. In car parks, they’re typically designed to the vehicle barrier loads in AS/NZS 1170.1, which are based on 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 a poor fit for forklift areas, while its 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. Thanks to its modular design, the system is highly customisable, easy to install and ideal for ongoing maintenance.

Space-saving: ForkSafe barriers are 90mm wide, which reduces the amount of operational space they occupy.
Modular and easily modifiable: The system is 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: PAS 13 is a testing method specifically designed to measure barrier strength and durability against forklift and other MHE impact in industrial environments, not just vehicles.

ForkSafe vs W-beam barriers: key differences

Understanding 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.

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:

the environment you’re installing into, e.g. a warehouse, car park, 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 from a car park or state highway.

Before installing any barrier, step back and ask yourself the questions above. Match the barrier to your environment, whether that’s W-beam, ForkSafe or another option. That way you avoid wasted spending, protect your people and make sure the solution genuinely does the job you expect it to.

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

FAQs about W-beam (Armco) barriers

What is a W-beam barrier?

A W-beam barrier is a heavy-duty steel barrier named after the W-shaped profile of its rail. It’s commonly used on roads and motorways, in car parks with heavy vehicle traffic, and outside facilities where trucks come and go.

Is Armco the same as a W-beam barrier?

Armco is a brand name, but it’s widely used to describe W-beam barriers in general. W-beam refers to the style of barrier describing its distinctive W-shaped profile of the corrugated steel rails. So when people say “Armco,” they usually mean a W-beam barrier.

Can W-beam barriers be used in warehouses?

They can, but they’re not the best fit. W-beam barriers are designed for vehicle impacts rather than forklifts and other materials handling equipment (MHE). Their bulky design, up to 300mm wide, also takes up valuable operational space you could otherwise use.

Why aren’t W-beam barriers ideal for forklift areas?

W-beam barriers are designed around impacts from cars and other vehicles, not forklifts and MHE. For areas where forklifts operate near people or assets, look for barriers tested in accordance with PAS 13, which covers forklift and MHE impacts in industrial environments.

How much space does a ForkSafe barrier save compared with W-beam?

ForkSafe barriers are 90mm wide, compared with up to 300mm for W-beam barriers. In a busy warehouse or logistics centre, that difference frees up valuable operational space.

What is PAS 13?

PAS 13 is the internationally recognised code of practice for industrial safety barriers. Its testing method measures barrier strength and durability against forklift and MHE impacts, not just vehicles.

What is Crumple Zone Technology?

Crumple Zone Technology (CZT) is a unique feature of ForkSafe barriers. It’s designed to absorb impact, reduce shock to forklifts or MHE, and help protect your concrete floor from damage.

How do I choose between W-beam and ForkSafe barriers?

Start with what the barrier needs to do. W-beam suits roads, car parks and truck movement areas. ForkSafe is designed for forklifts and MHE in warehouses, plants and logistics centres. Consider your environment, vehicle types, available space, traffic volume, and where vehicles and pedestrians intersect.

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.

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.

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