Rack Armour®

Product Details

The original racking upright protector

Exposed pallet racking uprights are among the most frequently damaged assets in any warehouse. Forklift trucks and pallet trucks operating along racking aisles create a constant risk of impact. Each collision that goes unaddressed weakens the upright and increases the risk of a more serious structural failure over time.

Rack Armour® was developed specifically to address this risk. It is the original upright protector, with over 20 years of proven performance across warehouse, distribution and industrial environments worldwide. Independent testing to international standard FEM 10.2.16 demonstrates that the Rack Armour® guard protects the upright from noticeable damage when subjected to impacts typical of MHE operating along racking aisles, with testing data indicating a reduction in racking damage of up to 80%. Rack Armour® works. It sits on the upright, takes the hit and reduces the damage before it becomes a compliance issue.

Twin-action design: HDPE and foam construction

Rack Armour® is manufactured from high density polyethylene with an internal foam layer. The shaped HDPE outer shell diverts impact energy around the rack leg rather than through it. Any remaining impact energy is then absorbed by the interior foam until it is fully diffused. This twin-action protection maintains the structural integrity of the racking system under repeated contact.

Unlike metal barriers, Rack Armour® cannot be knocked off when brushed by vehicles. The material is impervious to moisture, mould growth, corrosion, acid, alkaline and most solvents. It requires no repainting, no fixing replacement and no ongoing maintenance. The guard is fully recyclable, non-toxic and suitable for use in food production facilities and freezer environments.

Sizing, compatibility and installation

Rack Armour® is available in five width profiles to ensure a secure fit across the full range of pallet racking types in use today.

• Euro A fits front-facing uprights up to 87mm.
• Euro B fits up to 100mm.
• Euro C fits up to 110mm.
• Euro D fits up to 120mm.
• Euro E fits up to 135mm.

Both 300mm and 600mm heights are available across the standard range, with bespoke sizes available on request. Euro D and E 600mm high as standard (Bespoke sizes available on request). The guard fits by hand with no tools or additional fixings required and installs in seconds. It is also transferable between racking systems if the site layout changes, making it a flexible long-term investment rather than a fixed installation. Where upright inspections are required, the guard unclips or slides up without full removal, keeping inspection access straightforward.

Colour options are Hi-Vis Yellow and Safety Yellow as standard. Bespoke colours and branded label options are available on request, subject to minimum order quantities and pricing on application.

Suitable for the most demanding environments

Rack Armour® performs across ambient, chilled and freezer environments, covering the full range of conditions found in general warehousing, cold storage, food manufacturing and logistics facilities. Its resistance to moisture, mould and chemical exposure makes it a practical long-term choice for environments where metal barriers would require regular inspection and maintenance to remain serviceable.

Supporting racking safety and compliance

Under the Provision and Use of Work Equipment Regulations 1998 and HSE guidance document HSG76, employers are required to maintain storage equipment in a safe condition and take reasonable steps to prevent damage that could compromise structural integrity. Damaged racking uprights are one of the most commonly cited findings in warehouse safety inspections, and unaddressed damage can escalate from an amber to a red risk classification under SEMA guidelines, requiring immediate offloading and repair.

Rack Armour® provides a physical control measure at the upright itself, reducing the frequency and severity of impact damage before it becomes a compliance issue. For facilities managers, H&S managers and specifiers, installing upright protection across racking bays demonstrates a proactive approach to racking safety and supports the requirement to maintain storage equipment in an efficient and serviceable condition. For sites subject to SEMA-approved racking inspections, having upright protection in place at the most vulnerable points strengthens the overall safety and maintenance record for the installation.