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IT ARMORFLEX™ Polymer Crash Barrier · Mixed-Fleet Fulfilment
Painted Lines Cannot Hold an AMR–Forklift–Picker Aisle
A million-AMR fulfilment floor (Proteus-class) cannot rely on painted lines and operator training when humans, forklifts and autonomous robots share every narrow aisle. ARMORFLEX™ polymer FCBarrier DR double-rail and SR single-rail segments install a continuous, self-rebounding physical boundary that absorbs roughly 80% of strike energy and recovers its shape — protecting the picker at the rack face and the AMR pilot from a fork-related secondary hit.
Mixed-Fleet Aisle Spec at a Glance
Pick the rail height and segment count by the traffic that crosses the line, not by the painted-line width that runs between the racks today. The table below maps a real mixed-fleet aisle to the FCBarrier segment that already lives on that line.
| Aisle traffic | FCBarrier segment + what it does |
|---|---|
| Pedestrian picker walking beside an active AMR lane | SR Series single rail — slim ~80–100 mm diameter post on a bolt-down base plate; one horizontal yellow rail stops slow AMR drift and pedestrian step-over at the rack face. |
| Pedestrian crossing into a forklift traverse lane | DR Series double rail — two horizontal yellow rails on full-height black posts; absorbs fork tip, pallet jack and low-speed forklift nudge, then rebounds to service. |
| Heavy forklift impact zone at the rack-end frame | DR Series heavy — taller post, reinforced base plate; rated up to 28,950 J strike (8 t forklift at 9.6 km/h) on the rack end before the floor suffers. |
| AMR docking cell, door frame, column or dock-door post | CTR Series column protector — square-section closed contour; survives repeated AMR contact and door impact without permanent deformation. |
| Pedestrian-only safety barrier at pallet jack or conveyor entry | TR Series traffic rail — pedestrian barrier version of the DR rail for fork-free walkways and pick zones. |
What the Polymer Hard Boundary Buys You on a Mixed-Fleet Floor
DR Double Rail on the AMR-to-Pedestrian Edge
DR double-rail runs two horizontal yellow rails on black steel posts at the AMR-to-pedestrian edge, set on bolt-down base plates that survive the same floor-anchor treatment your existing painted-line layout uses today. ARMORFLEX™ polymer absorbs the impact and rebounds — the barrier stays in service after the strike, the AMR halts on its own safety field, and the floor does not need a weld-out replacement the way a deformed steel rail does. That is the difference between a hard divider that protects a million-AMR floor and a painted line that only reminds people to be careful.
SR Single Rail Where the Aisle Is Already Narrow
SR single-rail installs a single horizontal yellow rail on the same floor-anchored post, sized to keep the slim profile your fulfilment centre already designed for narrow aisles. The post cross-section is small enough not to steal pallet-face width or shrink the AMR turning radius — that is the slim profile that lets you keep the high-density layout the warehouse was originally engineered for, instead of trading rack capacity for a chunky steel guard. Painted lines never protected width either, but the slim FCBarrier post means you do not pay for the protection in lost pallet positions.
Where Mixed-Fleet Fulfilment Floors Put FCBarrier to Work
- AMR docking lane beside a pedestrian pick zone — DR Series double rail on the AMR-to-picker edge; absorbs repeated AMR nudges and one-off fork-tip strikes from a pallet jack.
- Rack-end frame in front of the picker station — DR Series heavy; rated up to 28,950 J so a misaligned forklift cannot take out the rack upright and the picker behind it.
- Tight cross-aisle between two picking zones — SR Series single rail; slim profile keeps the AMR turning radius intact while separating the two pick zones.
- Door frame at the AMR battery swap room — CTR Series column protector; closed contour survives the repeated low-speed contact of AMRs entering and leaving.
- Pallet jack lane beside a conveyor entry — TR Series traffic rail; pedestrian-facing version of the DR rail on a fork-free walkway.
The same modular spec that protects a Proteus-style AMR docking lane also protects the rack-end frame in front of the picker, because both sit on the same hard-boundary, self-rebounding polymer spec — not on two different paint cans.
Spec Sheet and Drawing Pack
Request the FCBarrier mixed-fleet aisle spec sheet — segment selection table, base-plate anchor pattern, and the ARMORFLEX™ Joule ladder for SR / DR / TR / CTR. Drawings include bolt-down base plate dimensions, post spacing, and the slim-rail widths that fit your existing narrow aisle without shrinking pallet-face or AMR turning radius.
Plan the AMR–Forklift–Picker Aisle With a Hard Boundary, Not a Painted Line
Send your aisle plan and AMR route map. We return a FCBarrier segment layout — SR slim, DR dual, CTR column — sized to the Joule rating your floor actually sees, with mortise-and-tenon quick-release so the boundary moves when the floor reshuffles.
