Protecting a Modern Distribution Centre from Impact Damage
Designing a solutions-led protection package for a high-volume fulfilment site
Understanding the challenge. 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:
- HR50 Pedestrian Handrails, modular pedestrian railings defining walkways and protecting critical pipework and storage zones.
- 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 Yellow 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.
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. PVC Car 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 Pedestrian 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
Improved safety and efficiency
- 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.
