Warehouse Safety Matting: UK Guide to Pedestrian Protection

Every year, workplace transport incidents in UK warehouses cause serious injuries and deaths. The Health and Safety Executive says poor separation between pedestrians and vehicles remains a top cause of these accidents. Barriers, signs, and training all help. But the floor beneath your workers’ feet is often missed as a key safety measure.

This guide shows how warehouse safety matting can boost pedestrian protection. It also covers traffic zone visibility and helps facilities managers meet UK health and safety laws.

The Scale of Warehouse Transport Incidents

The latest HSE stats for 2024/25 show:

• 124 workers killed in work-related accidents
• 680,000 working people hurt at work
• 40.1 million working days lost to injury and illness
• £22.9 billion cost to the UK economy each year

Slips, trips, and falls make up about 37% of reported workplace injuries. They also cause 28% of workplace deaths. In warehouses, these risks grow when forklifts and pallet trucks are added to the mix.

Forklift accidents cause multiple deaths each year. Pedestrian strikes are a big part of these incidents. The HSE says proper separation of forklifts and pedestrians is a legal duty, not just advice.

Legal Framework: What the Regulations Require

Several UK laws cover workplace transport safety and floor conditions:

The Workplace (Health, Safety and Welfare) Regulations 1992

These rules say that:

• Traffic routes must suit the people or vehicles using them
• Pedestrians and vehicles must use routes safely
• Routes must stop pedestrians and vehicles from crossing paths in dangerous ways
• Where paths cross, proper crossing points must exist

The Provision and Use of Work Equipment Regulations 1998 (PUWER)

PUWER requires safe use of work equipment, including vehicles. Employers must put control measures in place.

The Management of Health and Safety at Work Regulations 1999

Employers must do risk assessments and apply control measures that match the risks found.

HSE Guidance on Workplace Transport

HSE guidance states that keeping pedestrians and vehicles apart is the best way to protect workers. Where full separation isn’t possible, use barriers, signs, and floor markings.

How Warehouse Safety Matting Supports Compliance

Industrial matting does several jobs in a warehouse traffic management system:

1. Visual Zone Marking

Colour-coded warehouse safety matting creates clear boundaries. You can easily see where pedestrian walkways end and vehicle areas begin. Unlike painted lines, which wear out fast under forklift traffic, durable matting stays visible much longer.

Common colour coding:

Zone Type	Typical Colour	Use
Pedestrian walkways	Yellow or green	Safe walking routes
Vehicle areas	Grey or black	Forklift zones
Hazard zones	Red	No-go areas
Crossing points	Yellow/black stripes	Controlled crossings
Loading bays	Blue	Goods in/out

2. Better Slip Resistance

Warehouse floors get dangerous when wet with water, oil, or spills. Industrial safety matting with good slip resistance gives a safe walking surface in all conditions.

Slip resistance in the UK uses the Pendulum Test Value (PTV) per BS EN 16165. The UK Slip Resistance Group rates floors as:

• PTV 36+: Low slip risk
• PTV 25-35: Medium slip risk
• PTV 24 or less: High slip risk

Good warehouse safety matting should score PTV 36 or higher when wet and dry. For areas prone to spills, choose products tested to EN 13552.

3. Anti-Fatigue Benefits

Anti-fatigue matting in pedestrian areas keeps workers in safe zones. Standing on hard concrete for hours hurts. This leads workers to take shortcuts through vehicle areas. Comfy walkways help people follow the rules.

4. Tactile Feedback

The feel of stepping from concrete onto matting tells workers they’ve crossed a boundary. This helps a lot in noisy places where alarms might be missed.

Matting Specs for Warehouse Use

Not all industrial matting works in busy warehouses. Check these specs:

Load Bearing

Pedestrian walkway matting must handle the odd vehicle overrun. Look for products rated for pallet truck and forklift wheel loads. Heavy-duty mats can hold up to 10 tonnes. Some handle 44-tonne HGV traffic.

Thickness and Edge Profile

Matting should be thick enough to last and reduce fatigue. But not so thick it trips people. Products from 9mm to 22mm work well for pedestrian use. Bevelled edges cut trip risks where matting meets the floor.

Material Types

Nitrile rubber: Great oil and chemical resistance. Good for engineering and auto settings.

Natural rubber: Solid all-round choice. Best anti-fatigue feel. Less resistant to oils.

PVC (including recycled): Tough, chemical resistant, many colours. UK-made recycled PVC offers good performance and helps the planet.

Polyurethane: Top anti-fatigue performance. Very durable. Costs more.

Interlocking vs Roll Matting

Interlocking tiles work well for complex layouts. You can swap damaged sections easily. Roll matting covers big areas fast but needs cutting for custom shapes. For defined pedestrian walkways, interlocking warehouse safety matting often gives better value.

Setting Up a Zone-Based Flooring Plan

Good warehouse traffic management needs a clear approach:

Step 1: Traffic Flow Analysis

Map all vehicle and pedestrian movements in your facility. Find:

• Regular forklift routes and turning spots
• Pedestrian access points
• Places where paths must cross
• High-risk areas (blind corners, dock doors, racking aisles)

Step 2: Zone Definition

Set up clear zones based on your traffic study:

• Pedestrian only: Routes where vehicles never go
• Vehicle only: Areas where pedestrians shouldn’t be during work
• Controlled crossings: Set points where pedestrians may cross vehicle routes
• Mixed-use areas: Where full separation isn’t practical

Step 3: Flooring Selection

Pick the right warehouse safety matting for each zone:

• High-visibility matting for pedestrian walkways (yellow is standard)
• Different colours at crossing points
• Slip-resistant surfaces everywhere
• Anti-fatigue features where workers stand for long periods

Step 4: Installation

Make sure of proper fitting with:

• Secure fixing to stop movement under traffic
• Good edge treatment to prevent trips
• Correct alignment with barriers and signs
• Space for maintenance access

Step 5: Add Other Controls

Flooring should work with other traffic management tools:

• Physical barriers at zone edges
• Signs showing pedestrian and vehicle routes
• Speed limits and one-way systems
• Crossing procedures and training
• Warning systems where budget allows

Maintenance and Inspection

Industrial matting needs regular care to stay safe:

Daily Checks

• Look for damage, lifting edges, or shifted mats
• Remove debris that could cause slips or trips
• Clean up spills that could reduce grip

Regular Maintenance

• Deep clean as the maker suggests
• Replace damaged tiles or sections
• Re-fix loose edges
• Watch wear patterns that might show changed traffic flows

Keep Records

Document:

• Install dates and specs
• Inspection schedules and results
• Maintenance work done
• Repairs and replacements

These records support your compliance and show due diligence if an incident occurs.

Cost Factors

Quality warehouse safety matting is an investment. Weigh the cost against:

Direct incident costs: Injury payouts, legal fees, HSE action, and possible prosecution.

Indirect costs: Lost output, retraining, equipment damage, and higher insurance.

Operational gains: Less worker fatigue, better productivity in picking areas, and lower upkeep costs versus painted floor markings.

UK-made matting from 100% recycled materials, like the Safe-Flex range, offers good pricing. It also supports green goals and cuts supply chain hassle.

Summary: Key Specification Points

When choosing warehouse safety matting for pedestrian protection and traffic zones, ensure:

1. Slip resistance: PTV 36+ wet and dry
2. Load rating: Can handle occasional vehicle overrun
3. Visibility: High-contrast colours for clear zones
4. Durability: Suits your traffic level and spill exposure
5. Edge treatment: Bevelled edges to cut trip risks
6. Material: Chemical resistance that matches your work
7. Installation: Secure fixing and pro finish
8. Compliance: Meets relevant BS and EN standards

A smart flooring plan, paired with barriers, signs, and training, creates a full traffic management system. It protects your workers and shows your commitment to health and safety.

Next Steps

Reviewing pedestrian safety in your warehouse? Consider:

• A formal traffic flow assessment
• Checking your current floor condition and slip resistance
• Looking at how well your current zone markings work
• Talking to an industrial matting expert about solutions

Maximum Matting’s Safe-Flex range of interlocking tiles is made in the UK from 100% recycled PVC. It provides durable, slip-resistant surfaces ideal for pedestrian walkway marking. With high-visibility yellow bevelled edges and various surface textures, Safe-Flex systems fit right into your warehouse traffic management plan.

Contact our technical team for specification advice tailored to your facility.