Safety Management / Layout Design Guide

5-1. Safety Equipment, Management, and Pedestrian/Vehicle Separation Design in Logistics Facilities

1. Major Safety Equipment Inside the Warehouse and Around Berths

Safety equipment and safety management in logistics facilities are the keys to preventing occupational accidents (collision accidents with forklifts and large vehicles, collapse/falling of stored goods, falls from high-place work, etc.) and maintaining a workplace environment that complies with the Industrial Safety and Health Act.

1.1 Major Safety Equipment in the Warehouse Area

In spaces where workers and forklifts or AGVs co-exist, "pedestrian/vehicle separation" and "prevention of contact and falls" are reinforced from the hardware side.

• Pedestrian/Vehicle Separation Guardrails and Protective Fences: High-strength guard poles and guardrails that physically isolate the forklift driving path from the worker walking zone.
• Forklift Collision Prevention Alerts (AI Cameras / Radar): Equipped with ultrasonic sensors and AI cameras, these issue warnings with alarm sounds and LED strobes (revolving lights) when a worker approaches a blind spot.
• Rack Fall Prevention Protectors and Nets: Guard protectors are attached to the pillars of nestainers and pallet racks to prevent total rack collapse due to collisions by forks or wheels. Nets to prevent load collapse are stretched over the back and sides.
• Safety Equipment at Openings and Intersections: "Ultra-wide angle curve mirrors" and "motion sensor-linked LED warning lights" are installed at intersections that become blind spots at exits. For the loading opening on the mezzanine (middle floor), an interlock-type safety gate for fall prevention is adopted.

1.2 Safety Equipment in Truck Berths and Exterior Areas

Prevents personal injury accidents and damage to the building during reversing, moving, and unloading of large vehicles.

• Auto Truck Lock (Vehicle Wheel Chock Device): Automatically secures the rear tires when a truck docks, physically preventing accidents caused by mistaken departures or loose foot brakes during work.
• Dock Lights + Berth Communication Signals: High-brightness LED dock lights that illuminate the inside of containers, and traffic lights (red/blue lamps) installed in conjunction inside and outside the berth. Intuitively presents the work status.
• Truck Guidelines and Wheel Chock (Car Stopper) Blocks: Ground white lines and rubber stoppers for safe guidance to the appropriate docking position.

2. Safety Management System and Operational Rules (Software Aspect)

In addition to introducing equipment, organizational operation management in accordance with the Ordinance on Industrial Safety and Health is essential.

• Implementation of a Health and Safety Committee and "Risk Assessment": Workplaces with 50 or more workers regularly employed hold a "Health and Safety Committee" every month. They operate a risk assessment that tallies near-miss incidents to identify and improve hazard factors.
• Forklift Safety Management Regulations: Strict enforcement of driving by qualified personnel, mandatory pre-start inspections, and digital governor control of the indoor speed limit (e.g., 8km/h to 10km/h or less).
• 5S Movement (Sort, Set in order, Shine, Standardize, Sustain) and Safety Signs: Strict enforcement of orderliness through color line painting on the floor (clear indication of driving paths, walking paths, storage areas, and no-parking areas in front of fire hydrants/under shutters).

3. Layout Design Standards and Aisle Widths for Pedestrian/Vehicle Separation

Pedestrian/vehicle separation in logistics warehouses is an important measure to prevent personal injury accidents and maximize work efficiency. This section explains the aisle widths and layout design standards based on the standards of the Ordinance on Industrial Safety and Health and practical design guidelines.

3.1 Design Standards for Aisle Width

Aisle widths differ between the "legal minimum standard" and the "recommended value necessary for safe operation." Design is done anticipating the forklift model (vehicle width of approx. 1.1m to 1.3m) and cargo width (pallet width of 1.1m to 1.2m).

Type of Aisle	Legal Minimum Standard (Ordinance on Industrial Safety and Health, etc.)	Practical Recommended Width for Design	Calculation Basis / Operational Points
Dedicated Pedestrian Aisle	0.8m or more (Articles 542/543)	1.2m - 1.5m	Assumes workers passing each other (1.2m) or concurrent use of pushing handcarts (1.5m).
Forklift Only (One-way)	Vehicle width + 0.5m on left & right	2.8m - 3.5m	Secure 2.5m+ for reach trucks and 3.0m+ for counter-balance trucks.
Forklift Facing (Passing each other)	Vehicle width × 2 + 0.5m on left & right	4.0m - 4.5m or more	The main aisle (main traffic line) is standardly 4.5m or more.
Pedestrian/Vehicle Shared Aisle (Coexistence Area)	Vehicle section + Pedestrian zone separation	4.0m - 5.0m	Side-by-side arrangement of facing lifts (4.0m) + Pedestrian zone (1.0m).

3.2 Three Major Principles of Pedestrian/Vehicle Separation Layout

By using physical isolation and clear visibility, the chances of people's and vehicles' traffic lines crossing are minimized.

• Physical Blocking (Hardware Separation): Isolate the walking zone not just with painted lines, but with steel pipe protective guardrails or fences at least 1m high. Always install guard poles in blind spots.
• Grade Separation and Dedicated Multi-level Gates: Install "swing gates (with interlocks)" or "sensor-linked automatic gates" at points crossing the driving path to physically enforce temporary stops.
• Continuous Unidirectional Traffic Lines (One-way): To prevent passing accidents, the interior of aisles (passages between shelves) principally adopts a "one-way" layout.

3.3 Standard Rules for Floor Painting (Coloring)

• Green: Dedicated pedestrian aisles (walking zones).
• Yellow: Forklift driving paths and division lines.
• Yellow/Black Hatching (Tiger Stripe): Danger areas / Strictly prohibited leaving areas (under fire shutters, in front of fire hydrants, near emergency exits).

3.4 Safety Measures Between Racks (Aisles)

• Blind Spot Countermeasures for Right-angle Intersections: Install "ultra-wide angle mirrors" and "motion sensor-linked revolving lights" at the corners of racks.
• Entry Restrictions for Aisles During Work: During loading/unloading work onto high-rise racks, stretch intrusion prevention measures such as accordion poles across both ends of the aisle to completely block pedestrian entry.