From Frequent Rack Damage to Zero Incidents — Reinforced‑Base Metal Guard Fence Saves a Distribution Center

A large e‑commerce distribution center had recurring problems: during peak season, forklifts reversing or turning sharply in narrow aisles often clipped pallet racks or misplaced pallets, causing product damage and downtime. The management tried warnings, floor markings, and plastic bollards — none of which prevented collisions. In one incident they lost a high‑value order batch due to a toppled rack. That triggered a safety‑upgrade project.

Warehouse Challenges: Heavy Loads, Tight Spaces & High Traffic

In a busy warehouse with mixed pedestrian and forklift traffic, any collision can lead to costly damage. Impact barriers need to resist not just a single collision, but repeated impacts over time. According to warehouse safety best practices, properly designed barriers must absorb impact energy, not break or collapse, to prevent subsequent structural failure. (Safe Direction Warehouse Barriers) :contentReference[oaicite:4]{index=4}

Our Solution: Custom Steel Guard Fence with Reinforced Anchored Base

We specified a galvanized steel guard fence with thick base plates and concrete anchors, plus optional lower “fork-blocking” plate to avoid forklift forks penetrating beneath fence. The fence was installed along the busiest aisles, around sensitive racks, and near pedestrian walkways to clearly separate zones and prevent collisions.

Installation & Safety Compliance

The installation included pre‑drilled anchor bolts into reinforced concrete floor, and welding of fence base‑plates for maximum rigidity. After installation, the fence withstood multiple simulated impact tests, passing standards for industrial impact barriers. Heavy‑duty barriers like this are recommended by industrial safety experts and fence manufacturers for areas with high forklift traffic and material handling. (Damotech High‑Efficiency Steel Protection Fence) :contentReference[oaicite:5]{index=5}

Results: Zero Collisions, Lower Maintenance Costs, Safer Workplace

Over the next 9 months, the distribution center reported **zero** new rack‑collision incidents in the protected zones. Maintenance costs related to rack repair fell by 95%. Inventory loss and downtime were eliminated in those zones. Employees reported feeling safer, and productivity increased since fewer interruptions occurred.

Client Feedback & Recommendation

The operations director said: “Investing in that reinforced‑base metal fence was one of the smartest decisions we made. It saved us from recurring damage and improved workflow safety — ROI was evident within a single quarter.”

If your warehouse or logistics center still relies on flimsy rails, plastic bollards, or floor markings — you risk costly collisions, inventory damage, and downtime. A properly designed metal guard fence with reinforced base and concrete anchoring is the most reliable solution. Contact us for a tailored design for your facility.

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