Why NexGen

Flexible Barriers vs Steel

NexGen Barrier is America's authorized partner for Raysan PolyCore™ — PAS 13 certified polymer barrier systems that outperform steel on impact, maintenance, and total cost of ownership.

Impact tested

Up to 40,000 J

Product range

66+ configurations

Install rate

80–100 m / shift

Operating temp

−40°C to +60°C

Why Standards Matter

Industrial workplaces face daily risks from moving vehicles, heavy equipment, and mixed traffic patterns. Safety barriers are the last line of defense — but only if they are designed, tested, and installed to perform under real-world impact conditions. Standards like PAS 13 exist because not all barriers are created equal. A barrier that looks adequate may fail catastrophically when struck by a loaded forklift at operating speed.

Independent certification from bodies like TÜV-NORD verifies that products have been tested under controlled conditions — measuring impact resistance, deflection, and penetration. This gives facility managers, safety officers, and insurers confidence that protection systems will perform when needed.

Why Independent Certification Matters

Manufacturer claims are not enough. Third-party certification ensures products meet published standards through rigorous testing — not marketing assertions. For NexGen customers, every PolyCore™ barrier we supply carries PAS 13 certification verified by TÜV-NORD, along with ISO quality, environmental, and safety management certifications from our manufacturing partner Raysan.

Certification

TÜV-NORD PAS 13

Code of practice for industrial safety barriers

PAS 13:2017 is a code of practice published by the British Standards Institute (BSI) that provides guidelines for the selection, installation and use of safety barriers in workplace environments. It was developed in collaboration with industry experts to address the growing need for standardized safety measures in areas where vehicles and pedestrians interact.

The standard includes test methods for measuring the impact resistance of safety barriers, including impact tests, deflection tests, and penetration tests. Products tested to PAS 13 demonstrate verified performance under controlled conditions — giving facility managers confidence that barriers will perform as expected when struck by workplace vehicles.

NexGen PolyCore™ barriers are PAS 13 certified through independent testing by TÜV-NORD, one of the world's leading certification bodies. This certification is increasingly referenced by insurers, safety auditors, and corporate EHS teams when evaluating warehouse and manufacturing facility protection.

Certification

ISO 9001:2015

Quality Management System

ISO 9001:2015 is the international standard for quality management systems. It provides a framework for consistent product quality, customer satisfaction, and continuous improvement across all business operations.

Our manufacturing partner Raysan maintains ISO 9001 certification, ensuring that every PolyCore™ barrier profile is produced under documented quality control processes — from raw material selection through extrusion, testing, and packaging.

For NexGen customers, this means every barrier system we supply meets the same rigorous quality standards used in facilities across Europe, the Middle East, and now the United States.

Certification

ISO 14001:2015

Environmental Management System

ISO 14001:2015 sets the framework for effective environmental management. Certified organizations systematically identify, manage, and reduce their environmental impact across production and operations.

PolyCore™ barriers are manufactured under ISO 14001 certified processes, supporting our commitment to 100% recyclable materials and sustainable production. At end-of-life, PolyCore™ components can be returned to the recycling stream rather than sent to landfill.

For companies with corporate sustainability targets, choosing ISO 14001 certified barrier systems supports ESG reporting and demonstrates responsible procurement.

Certification

ISO 45001

Occupational Health and Safety Management System

ISO 45001 is the global standard for occupational health and safety management. It helps organizations proactively reduce workplace risks, prevent injuries, and create safer working environments.

Barrier systems are a critical component of workplace safety infrastructure. ISO 45001 certified manufacturing ensures that the products protecting your employees are themselves produced under rigorous safety management practices.

NexGen works with facilities to align barrier layouts with OSHA requirements, internal safety policies, and industry-specific standards — from general warehousing to food, pharma, and aviation environments.

Certification

REACH SVHC

Chemical safety testing

REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) is the EU regulation governing chemical safety. SVHC (Substances of Very High Concern) testing verifies that products do not contain hazardous substances above permitted thresholds.

PolyCore™ polymer formulations have been tested and verified compliant with REACH SVHC requirements. This is particularly important for food, beverage, pharmaceutical, and chemical processing facilities where material safety is non-negotiable.

The non-porous surface of PolyCore™ also prevents microbial build-up, making it suitable for hygienic environments where cleanability and chemical resistance are essential.

NexGen Flexible Barriers vs Steel Barriers

In America, steel remains the default barrier material — but it creates more problems than it solves. Steel barriers dent permanently on impact, transfer energy into floors and rack systems causing structural damage, require ongoing painting and galvanizing to prevent rust, and are unsuitable for food, pharmaceutical, and clean-room environments where paint flaking and corrosion contamination are unacceptable risks.

PolyCore™ polymer barriers absorb impact energy within the flexible material, rebound to their original shape after hits below the endurance limit, and continue protecting after multiple impacts. With PAS 13 tested protection up to 40,000 joules, they compete directly with steel on performance while eliminating lifetime maintenance costs.

Steel Barriers

• Constant rust and corrosion — requires painting and galvanizing
• Permanent deformation after major impacts — single-use protection
• Transfers impact energy to floors, foundations, and racking
• Not suitable for food, pharma, or clean-room environments
• Heavy — difficult to relocate as layouts change
• Paint flaking creates contamination risk in hygienic areas

PolyCore™ Barriers

• Maintenance-free — only occasional dust wipe required
• Multi-impact protection up to 40,000J — rebounds after hits
• Absorbs energy, protects floors, equipment, and structures
• Food-contact safe, anti-bacterial, UV and chemical resistant
• Modular — relocate and reconfigure with basic tools
• 100% recyclable at end-of-life

New Generation Flexible Barrier Systems

NexGen engineers calculate the plastic shape change limit for each environment based on carrier equipment type, weight, operating speed, and traffic patterns. PolyCore™ barriers resist all impacts below the calculated endurance limit and return to their original shape repeatedly — unlike steel which yields permanently on first significant impact.

100% Recycle
Maintenance Free
Economic
Hygienic
UV Ray Resistance
Flexible
Superior Impact Resistance
Fast & Easy to Demount
Corrosion Resistance
Chemical Resistance
Electrical Insulation
Modular Design
Longevity
Easy to Carry

Technology & Advantages

Superior Impact Resistance

Absorbs and dissipates impact energy in pendulum tests up to 40,000J. Verified performance under PAS 13 testing protocols.

Impact Absorbing Design

Dampens impact within the polymer structure, minimizing damage to connection points, floors, and adjacent equipment.

Zero Maintenance

No painting, galvanizing, or corrosion treatment. Self-coloured polymer will not fade, rust, or require recoating after impacts.

Modular Structure

Easily transported, installed, and reconfigured. Adapt barrier layouts as facility operations evolve without demolition.

Chemical & UV Resistance

Withstands oils, solvents, cleaning chemicals, and continuous UV exposure without degradation.

Food Contact Safe

Non-porous surface approved for direct food contact. Ideal for food, beverage, and pharmaceutical environments.

Frequently Asked Questions

Common questions about flexible barrier systems, PolyCore™ technology, and NexGen Barrier services.

Is flexible barrier safe?

NexGen PolyCore™ Flexible Barrier and Impact Protection Systems have been subjected to various crash tests for the most difficult conditions and equipment. According to the results obtained, it is much more reliable than metal competitors of the same cross-section.

Is flexible barrier economical?

Permanent deformation due to impact in PolyCore™ Flexible Barrier is very low probability compared to metal equivalents. It has a much longer life, requires no maintenance or repair, and damaged parts can be replaced easily. For these reasons, it provides cost advantage to businesses.

In America, how does NexGen compare to steel?

In America, our main competitor is steel. Our PolyCore™ barriers are maintenance-free, absorb impact energy rather than transferring it to floors and structures, and continue protecting after multiple impacts. Protective ranges up to 40,000J compete directly with steel.

How long is the assembly time?

PolyCore™ barriers are assembled much faster and easier than steel competitors. 2 personnel can assemble 80-100m of barrier in a shift. This time may vary according to barrier type.

Does NexGen Barrier fit every company's dimensions?

We produce special solutions and products for each company. Your needs and dimensions are determined by making an exploration in your facility, so you are served with tailor-made, fully compatible products.

Is flexible barrier environmentally friendly?

PolyCore™ Flexible Barrier Systems are produced with the principle of respect for tomorrow by choosing 100% recyclable materials. At end-of-life, products can be returned into the recycling stream.

Is it suitable for food contact?

PolyCore™ Flexible Barrier Systems have been found suitable for direct contact with food as a result of relevant laboratory tests. The non-porous finish prevents microbial build-up, making it ideal for food, pharmaceutical, and clean-room environments.

Is it suitable for chemical contact?

PolyCore™ Flexible Barrier Systems are characterised as highly resistant to chemical contact as a result of relevant laboratory tests. They withstand oils, solvents, and cleaning chemicals typically used in industrial settings.

Does the flexible barrier require painting and maintenance?

Thanks to its polymer structure, PolyCore™ will not be affected by UV rays or moisture, will not rust or corrode. In case of collisions, the self-coloured polymer material will stretch and return to its original state.

Can the flexible barrier be replaced or relocated?

It is possible to easily move your PolyCore™ barriers wherever you want at any time depending on the change of your needs. A modular fastening system enables rapid mounting and removal with basic tools.

What happens if my flexible barrier breaks?

When a PolyCore™ barrier is damaged, you can re-supply only the broken profile regardless of its size and replace the broken part with a new spare part in maximum 15 minutes.

Is there a removable and pluggable flexible barrier?

We offer a Slider Plate option for areas that need to be opened and closed to traffic quickly. You can remove and reinstall your flexible barrier in seconds.

Our Products

Eight product groups covering every industrial barrier application — from traffic management to rack protection, pedestrian safety, and soft protection.