Polymer vs. Steel Safety Barriers: What to Know Before You Choose

On the surface, polymer vs. steel barrier differences are obvious. It’s the underlying benefits and potential drawbacks of each that invite us to look deeper.

To level-set, polymer safety barriers are flexible, fixed polymer tube barriers made from impact-modified polypropylene, a semi-rigid material. Steel barriers are rigid, fixed steel powder-coat painted rails that can dent upon impact.

As we’ve stated elsewhere, there’s no one-size-fits-all safety barrier solution to cover every variable in your facility.

Safety is paramount in every situation. You get that with either steel or polymer.

You probably have several other things on your mind as you pick your path. Let’s talk through those.

Differences and similarities in steel and polymer barriers

This apples-to-apples comparison is a basic start in narrowing down your options for materials. You can also talk through your situation with an expert who will help address your unique concerns.

Note that all attributes below are specific to Rite-Hite safety barrier products.

Q: How resilient and safe is each material when an impact occurs?

STEEL: Material handling vehicles will dent and scratch steel in an impact. That equipment might also sustain damage, as the barrier isn’t very forgiving. When it fails, jagged steel is unsafe for workers in the vicinity. Steel also redistributes energy from the impact to the floor, its column or anything that comes between vehicle and barrier. This generates additional repair or maintenance costs.

POLYMER: Polymer will absorb almost all energy from impacts by that same material handling vehicle with little or no damage. Equipment won’t be any worse for a collision with round, lightweight polymer rails. Those rails are more forgiving than steel, bending to help preserve people or products caught in between — which spares you from additional repair or maintenance expenses.

Q: How much upkeep does each material take to keep performing as designed?

STEEL: Manufactured with a highly visible yellow powder coat, any scratches will have to be repainted yellow to remain effective. Any moisture in your facility can cause rust or corrosion over time, which alter visibility and sometimes structural integrity — steel needs to be kept dry. Dents can also adversely affect what barriers are designed to do and may call for replacement.

POLYMER: The material itself is manufactured in highly visible yellow all the way through. Stabilizers are part of that process to give it UV-light protection, so color doesn’t fade. Of course, polymer still requires regular cleaning to maintain full visibility. Moisture has no effect on its intended performance. Incidental impacts are unlikely to cause damage that requires attention.

Q: Which material has the best overall value — the highest return on investment?

STEEL: Steel has a low initial price point for the barrier itself. However, it’s prone to market volatility — supply chain disruptions, raw material supply, energy prices and tariffs all influence that dollar amount. So while you might get a good deal at purchase, replacing steel after your barrier is impacted or degraded could drive up the total cost of ownership in the long term.

POLYMER: While that up-front payment for polymer will be higher than steel, it will cost less over the course of its lifetime. Those rails are less likely to need replacement. If they do, the raw materials are rarely in short supply and can be manufactured easily and quickly. As noted above, the cost of preventative maintenance and repair will also be far less.

To be clear, there’s no one-size-fits-all safety barrier solution. These and other variables will factor into your ultimate decision for what’s best for your unique situation.

Breaking down the benefits

Polymer tube rails are manufactured in different sizes with unique attributes or applications.

Each size has a purpose, too. Rite-Hite’s GuardRite® Polymer Barrier product line has six models for various applications.

• LD – for pedestrian separation or light-duty applications
  • 48”-tall posts with two 4”-diameter rails
  • Absorbs light-duty vehicle impacts from carts and pallet jacks up to 15,000 lbs. (2 mph)

• HD – for separation and protection in high-traffic areas
  • 48”-tall posts with one 4”-diameter rail, one 6” diameter rail and one reinforced 6” diameter rail
  • Absorbs impacts from fork trucks up to 30,000 lbs. (3 mph)

• HD Plus – for separation in high-traffic areas with a need for ground-level protection
  • 48”-tall posts with one reinforced 6”-diameter rail plus one 12”-tall bottom rail assembly
  • Absorbs impacts from fork trucks up to 30,000 lbs. (3 mph)

• HDXL – for protection in areas with product stacking
  • 120”-tall posts with five 4”-diameter rails, one 6”-diameter rail and one reinforced 6”-diameter rail
  • Absorbs impacts from fork trucks up to 30,000 lbs. (3 mph)

• HDXL Plus – for protection in high-traffic areas with product stacking and a need for ground-level protection
  • 120”-tall posts with five 4”-diameter rails and one reinforced 6”-diameter rail plus one 12”-tall bottom rail assembly
  • Absorbs impacts from fork trucks up to 30,000 lbs. (3 mph)

• HDSR – for building infrastructure and equipment protection
  • 20”-tall posts with one reinforced 6”-diameter rail
  • Absorbs impacts from fork trucks up to 22,000 lbs. (3 mph)

GuardRite Steel is heavy-duty protection with a single or double rail.

• Steel – for separation and protection in both light- and heavy-duty applications
  • 23”-high single-rail system or 44”-high double-rail for extra protection
  • Absorbs impacts from vehicles up to 30,000 lbs. (4 mph)

Quantifying the decision

Steel is initially the more affordable option. But you can’t ignore long-term costs when collisions occur. Repairs, replacement and maintenance costs are higher for steel.

The value scales can quickly tip to favor polymer for total cost of ownership. Your future colleagues — and even your current ones — might thank you.

Whether considering safety barriers inside your facility or at the loading dock, anything is better than yellow lines painted on the floor. But what’s best for you won’t feel so subjective once you map out your organization’s top considerations in raising that yellow line.

Data-driven decisions will let you rest easier — and potentially persuade decision-makers to align on the best option for your safety barrier solution.

If you need to understand the value of your options more clearly, we’ll consult with you to address all variables and concerns.

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