Damage limitation
April 1st 2008

Simon Bradbury of Berry Systems looks at how an appropriate protection system can reduce expensive impact damage around the loading bay

With the potential mix of vehicles in a loading bay, it's hardly surprising that up to 25% of industrial accidents occur in this area.

Heavy goods vehicles, vans, forklift trucks and pedestrians are a potent combination at the best of times and all highly susceptible to impact damage (particularly pedestrians!) But apart from the damage to themselves, vehicle accidents can also lead to expensive repairs to ramps, walls, cladding and doorways – without necessarily any suggestion of negligence or carelessness. Accidents will happen in these areas, the important thing is to utilise the correct protection system to minimise the potential damage.

Follow the guide Even with modern driving aids, lining up an HGV into the right position at a loading bay is a skilled job that can be made easier by judiciously placed wheel guides, preferably mounted into the ground rather than just bolted down (unless the ground surface is particularly good). Make sure you choose guides with a good wall thickness as well, 5mm or more, or they'll just get crushed rather than guide the wheels of an HGV as intended. Protect the end of the loading bay and nearby walls with steel bollards.

As the vehicle gets closer to the bay the next consideration is a decent height guide or restrictor. At their simplest these can be just a goal post type structure, the same height as the loading bay door. This gets hit first and saves any structural damage to the building. Such products are effective but obviously prone to damage themselves and will need regular but cost effective repairs.

'Deluxe' versions incorporate a flexible top cross rail that is able to absorb some of the impact whilst making it obvious to the vehicle driver that he can't get through. This minimises the damage to the height restrictor and allows continuing functionality as well as reduced maintenance costs. The more sophisticated systems incorporate base guidance units as well to help eliminate side damage. It's also a good idea to fit 100mm or 150mm high rubber profiles in front of the bays to provide a positive stop for reversing vehicles. Be aware however that these may pose a trip hazard at other times for pedestrians, even if they shouldn't be in the area.

Once the HGV is in place attention turns to the forklift that's going to load it but in fact we need to consider what could happen when the bay is empty as well. It's remarkably easy (but very expensive) to drive a forklift off an empty bay and there are a number of ways of preventing this. Removable bollards are a simple option but, if they do their job they'll get hit and damaged.

Eventually the footings will take no more repairs and you're facing expensive 'rebuilding ' of the deck. More costly initially but cheaper in the long run are the various flexible bollards that are available although these are not generally as demountable and so can get in the way. We often install Hercules Bollards in these circumstances.

They are manufactured from an impact absorbing material and their unique design allows them to deflect up to an angle of 18 degrees when struck, so any chance of accidental impact damage is practically eliminated. They can also be connected with chains to provide a virtually impenetrable barrier that can be readily opened when required. These bollards are extremely strong, hence the name, and they can resist impacts from vehicles up to 10 tonnes. Once the vehicle has been moved, they return to their original position without any reduction in performance. An optional movement detector can also be installed in the bollard that will sound an alarm if a vehicle impacts.

On ramps any impact is likely to be a glancing blow and the best protection here is a safety barrier mounted on spring steel buffers. Integral handrails can be fitted as well. Don't make the mistake of using rigid posts here - you'll be continuously replacing bent rails without the deflection on impact that spring steel gives. You'll also do much more damage to the forklift.

Flexible systems The same advice applies for barriers to protect doorways, walls and machinery or plant. There are flexible systems available that will take the weight of HGVs as well as vans and forklifts. Be careful to check how they are tested though and at what impact points. It's fairly easy to design a system that's flexible - provided you don't hit the posts. In real life you can't guarantee that.

And don't forget pedestrians, the most valuable things of all. Fit integral handrails wherever pedestrians will walk, not just to give them guidance and added protection but to stop them falling over the barriers!

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