20 Nov 2025

The Most Durable Barrier Solutions Against Forklift Collisions

One of the most common accidents in storage and production areas is forklift collisions.
Forklifts are heavy-duty vehicles capable of moving at high speed while carrying loads, and an uncontrolled collision poses a serious safety risk to both employees and equipment.

Such incidents can cause racks to collapse, walls to be damaged, machines to malfunction, and even production to halt — resulting in both financial and operational losses for businesses.

Therefore, barrier systems resistant to forklift impacts have become indispensable safety elements in modern warehouses and factories.
With its high-strength flexible barrier technology, Raysan provides the most effective and long-lasting protection against forklift accidents.

The Impact of Forklift Collisions on Industrial Infrastructure

Forklift collisions in industrial facilities cause not only physical damage but can also bring production to a complete stop.

• Rack collapses: Can trigger chain reactions and falling loads on high storage systems.
• Machine damage: Leads to failures in production line equipment.
• Floor deformation: Causes cracks and vibration-related damage on concrete surfaces.
• Workplace accidents: Directly endanger employee safety.

Raysan has developed high-impact-absorbing barrier systems to eliminate these risks.
Its products absorb the kinetic energy generated by forklifts and other heavy equipment, protecting both the impacted surface and the barrier itself.

Flexible Barrier Technology: Intelligent Energy Absorption

The most important feature of Raysan barriers is their flexible polymer structure.
Traditional steel barriers transfer impact energy directly to the floor or structure, leading to deformation, cracks, or breaks.
Raysan’s flexible barriers, however, absorb impact energy and distribute it within their own body.

Advantages:

• Maintain their form after impact,
• Do not damage floors or walls,
• Eliminate the need for barrier repair or replacement,
• Reduce the risk of damage to forklifts.

As a result, Raysan barriers are not just obstacles — they are impact management systems that intelligently control collision forces.

Raysan Barrier Types for Forklift Safety

Raysan offers several complementary barrier systems designed specifically to protect against forklift impacts.
Each product can be customized to the facility layout and traffic intensity.

1. Impact Barriers

• Used in wall, machinery, and corner areas — the most common points of forklift contact.
• High impact resistance and long-lasting flexibility.
• Maintain their form even after multiple collisions.
• Modular design allows easy replacement of damaged parts.

These barriers serve as the primary line of defense in production lines with heavy forklift traffic.

2. Rack Protection Barriers

• Protect the lower sections of warehouse rack systems.
• Isolate rack legs from forklift collisions.
• Available in Delta, Zeta, and RackFort™ models for various floor layouts.
• Distribute impact energy to prevent rack collapse.

These systems are among the most widely used forklift safety solutions in storage facilities.

3. Pedestrian Barriers

• Separate forklift routes from pedestrian pathways.
• Enhance visual awareness and reduce collision risk.
• Modular structure allows flexible installation at desired lengths.

Pedestrian barriers eliminate human-machine contact, one of the leading causes of forklift-related accidents.

The Source of Durability: Polymer Material Technology

The high-density polymer material used in Raysan barriers offers significant advantages over traditional steel barriers:

Feature	Steel Barrier	Raysan Polymer Barrier
Impact Resistance	Rigid, bends after collision	Flexible, absorbs energy and returns to shape
Maintenance Requirement	Needs painting, welding, rust removal	Maintenance-free
Corrosion Resistance	High rust risk	100% corrosion-resistant
Floor Effect	Transfers impact energy to the ground	Distributes energy within its body
Service Life	2–3 years	Up to 10 years

These distinctions make Raysan barriers the most durable solution against forklift collisions.

Tested Safety: Certified Products

All Raysan barrier systems are tested in compliance with international quality and safety standards:

• TÜV NORD
• PAS 13
• ISO 9001
• REACH

These certifications confirm the impact resistance, chemical durability, and production quality of Raysan products — proving their reliability in protecting both people and equipment at a global standard.

Long Life, Zero Maintenance

In facilities where forklift collisions are frequent, durability alone is not enough — continuity is also essential.
Raysan barriers operate for years without requiring maintenance:

• They do not rust, fade, or decay.
• Suitable for both indoor and outdoor environments.
• Fully resistant to UV, moisture, oil, and chemicals.

Thanks to these features, Raysan barriers significantly reduce maintenance and replacement costs for businesses.

Smart Safety That Organizes Forklift Traffic

Another key function of barrier systems is to control forklift traffic.
Raysan products provide not only physical protection but also visual guidance:

• Their bright colors offer clear visibility for forklift operators.
• They define work zones precisely.
• They improve line-of-sight, preventing accidents before they occur.

These systems contribute to an organized, safe, and smooth traffic flow within warehouses.

Sustainable Safety Approach

Raysan combines safety with environmental responsibility.
All its barrier systems are produced from 100% recyclable polymer materials.

• Low energy consumption during production,
• Zero chemical maintenance requirement,
• Long lifespan ensuring minimal environmental impact.

Thus, Raysan ensures forklift safety not only for today but also for the sustainable industrial facilities of the future.

Economic Advantage: Maximum Savings in the Long Run

Every Raysan barrier used against forklift impacts provides direct financial benefits to businesses:

• Eliminates costs related to floor repair, paint, or welding,
• Shortens return on investment (ROI) since replacement is unnecessary,
• Minimizes production downtime.

With these features, Raysan barriers are more than a safety system — they are a profitable long-term investment.

Maximum Safety, Minimum Risk with Raysan

Raysan’s barrier systems against forklift collisions address every need of modern industrial facilities:

• Flexible design absorbs impact and protects equipment,
• Long-lasting and maintenance-free,
• Sustainable and environmentally conscious,
• Modular structure for easy installation and adaptability.

Each product is designed with a focus on human safety, equipment protection, and operational continuity.

Forklift collisions are among the most common — yet entirely preventable — risks in industrial facilities.
With its flexible polymer barrier systems, Raysan completely eliminates this risk, combining safety, efficiency, and sustainability.

Each Raysan barrier stands out with tested impact resistance and a maintenance-free lifespan — absorbing energy to protect both vehicles and infrastructure.

Ultimately, Raysan builds the future of industrial safety today, with barrier solutions that don’t just stop impacts — they manage them.