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Bollard Considerations for Warehouses & Manufacturing:

Protecting People, Property, and Productivity

In warehouse environments, safety and asset protection are non-negotiable. Warehouses are fast-paced, high-traffic facilities where forklifts, pallet jacks, trucks, and pedestrians move in tight spaces—often near expensive equipment and structural assets. One wrong move can result in costly damage or injury. That’s where bollards come in.

Strategically placed bollards offer physical protection and visual cues to guide traffic, shield infrastructure, and keep personnel safe. Below, we break down key bollard considerations for warehouse facilities across a variety of high-risk zones.

1. Equipment and Machinery Protection

Heavy-duty bolt-down bollards around sensitive machinery such as conveyors, compressors, control panels, and robotics help prevent forklift strikes and damage from pallet handling. Bollards should be:

  • Built for the level of risk

  • Brightly colored or marked with reflective tape

  • Installed with proper spacing to allow forklift clearance while still blocking direct access

2. Building Corners and Structural Columns

Blind corners and structural columns are prime collision points. Damaged corners can lead to compromised structural integrity, while repairs require downtime and cost. Use:

  • Corner-protecting bollards or U-shaped guards

  • High-visibility finishes

  • Embedded or bolt-down options depending on concrete thickness and slab construction

3. Pedestrian Walkways and Work Zones

Warehouses with pedestrian foot traffic must separate workers from powered industrial vehicles, like forklifts. Bollards help define safe zones such as break areas, packing stations, and walk paths.

  • Bolt down or flexible bollards can be used where occasional access is needed

  • Bolt-down and removable guardrail systems can be used to protect long runs of exposed area

  • Painted bollards in safety yellow or red increase visibility

  • Barrier rails integrated with bollards add extended protection

4. Overhead Door Protection

Dock doors and overhead doors are among the most frequently damaged warehouse elements. Forklifts trying to align with a door or rushing loads through can easily impact frames.

  • Install corner bollards flanking the door edges, set back just far enough to allow safe clearance

  • Use removable bollards if wide-load access is occasionally required

  • Consider overhead door bollard systems to minimize impact damage to the top and sides of overhead doors, inside and outside

5. Gas Lines and Storage Tanks

Unprotected gas lines or tanks pose a serious safety risk. A single hit can result in leaks, fire, or explosion.

  • Use high-strength embedded steel bollards around tanks or line manifolds

  • Ensure compliance with local fire codes or NFPA regulations

  • Use locking caps or for tamper resistance

6. Fork Guard Bollards (Rack-End Protection)

Forklift forks frequently cause damage to racking systems and inventory stored on the bottom levels. Use:

  • Low-profile fork stops or fork guards designed to block fork tips

  • Bollards at rack ends to prevent corner hits and structural collapse

  • Integrated rack protectors with bollard-style reinforcement

7. Parking Lots and Perimeter Areas

Outside the warehouse, bollards help control vehicle movement, protect parked trailers, and prevent accidental building strikes.

  • Surface-mounted or embedded bollards define traffic flow

  • Flexible bollards can reduce wear from incidental bumper strikes

  • Removable bollards, bollard chains or gates can control after-hours access

8. Gateways and Entrances

Controlled access areas such as gated entries, security checkpoints, and main entrances benefit from bollards to:

  • Protect gate operators and access panels

  • Prevent vehicle intrusion or ramming

  • Define traffic lanes for incoming and outgoing vehicles

Consider removable guard post bollards for flexible access control.

Additional Considerations:

  • Material selection: Carbon steel is standard for industrial use, but galvanized or stainless steel should be used in wet, cold storage, or corrosive environments.

  • Finish options: Urethane paint in high-visibility colors enhances durability and safety.

  • Reflectivity: Add reflective tape for enhanced night visibility.

  • Spacing and embedment: Match bollard size, embedment depth, and spacing to the type of threat (light carts vs. heavy forklifts).

  • Customization: Many applications require custom heights, anchoring methods, or base plates to align with facility layout.

The Bottom Line

Warehouse safety starts with proactive planning. Bollards aren’t just parking lot accessories—they’re critical safety infrastructure. Properly selected and placed bollards protect your people, equipment, and operations while minimizing downtime and expensive repairs.

Whether you’re designing a new facility or retrofitting an existing space, our team can help you select or customize the right bollard solution for your unique layout and risk profile.

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