Exposed elements of the storage system should have suitable protection fitted. This guidance is issued by SEMA and also by the HSE in HSG76. Suitable protection is especially important on exposed corners in areas of high activity such as uprights adjacent to main transfer aisles.
It might also include faces of racking that adjoin busy aisles with a lot of through traffic or areas of high activity such as racks adjacent to marshalling or despatch areas where rack contact is more likely. You shouldn’t need rack protection to all uprights, and your truck drivers should be capable of accessing storage racks without regular contact with the structure.
If they cannot, then they shouldn’t be at the wheel of a truck, and in such cases, retraining is the solution! And don’t forget that retrofitting protection will reduce available clearances, thereby increasing the likelihood of contact and possible damage.
Bear in mind that this protection is intended as a method of last resort and should not be seen as a positioning guide. There should never be regular contact between the truck/pallet and the rack structure. We will cover what sort of protection is suitable in another post.
When selecting protectors, we would always recommend a good heavy-duty freestanding guard, and when fitting, ensure adequate clearance off the upright.
Where guards are fitted too close to an upright, repeated impacts may cause ‘knifing’ damage as the guard flexes, concentrating all the force of the impact on the top edge of the guard.
This creates a high point impact where it hits the upright, resulting in disproportionate damage. Fitting too close will also restrict inspection of the upright, footplate, and floor fixings. SEMA recommends a minimum clearance of 25mm, with 40-50mm being preferred.
We do not recommend the cheaper clip-on type of guards that fit directly onto the upright.
They may be a quick and easy solution but are in no way as effective as solid, securely bolted freestanding guards and only provide limited protection. Furthermore, they must always be removed to allow regular inspection of the upright but can be extremely difficult to remove once fitted, so they are often simply left in place.
In our experience, this can do more harm than good since they can hide damage. Remember, just because one of these guards is fitted, there is no guarantee that there wasn’t any pre-existing damage or damage caused post-fitting. I’ve inspected many warehouses where these guards have been removed for my inspection, and the damage detected is well beyond what’s possible with the guard fitted.
End-of-rack runs may need more robust end-of-row protection that may take the form of Armco-type crash barriers or tubular guards. This is particularly important where pallets are stacked at the ends of runs since it is routine practice for drivers to stack pallets hard against end frames, and this damages the uprights, bracing, and loosens floor fixings. Again, a risk assessment will determine the need.
Understanding the Importance of Upright Protectors and High-Visibility Guards
Upright protectors are an essential aspect of pallet protection. In any busy warehouse racking environment, the likelihood of accidental contact between pallet trucks or forklifts and the racking uprights increases significantly. Properly installed upright protectors not only safeguard the structural integrity but also enhance safety by minimising the risk of collapse due to repeated impacts.
High-visibility protectors are particularly beneficial in areas with high activity levels. These protectors make it easier for truck drivers to navigate the working environment and identify potential hazards, reducing the likelihood of collisions. A high-visibility rack guard, combined with proper driver training, creates a safer and more efficient workspace.
Key Considerations for Racking Upright Protection
When implementing pallet protection measures, it’s important to focus on areas that are most vulnerable to damage. This includes:
Main Transfer Aisles:Â High-traffic areas where forklifts frequently move pallets.
Marshalling and Despatch Areas:Â Zones with increased activity and pallet movement.
End-of-Row Runs:Â Areas prone to collisions due to stacking practices or limited space.
Each of these areas should be assessed to determine the appropriate type of protection. Heavy-duty freestanding guards, Armco barriers, and tubular guards are some of the most effective solutions for these zones.
Avoiding Common Pitfalls in Racking Protection
While upright protectors and pallet protectors are essential, improper installation or reliance on subpar solutions can lead to more harm than good. For instance:
Inadequate Clearance:Â Guards fitted too close to the upright can cause concentrated damage and obstruct routine inspections.
Clip-On Guards:Â These may appear convenient but lack the durability and effectiveness of bolted freestanding guards. They also complicate the inspection process.
Neglecting Risk Assessments: Every warehouse environment is unique. Without a thorough risk assessment, it’s impossible to determine the right type and placement of rack protection.
The Role of Driver Training in Racking Safety
No amount of upright protection can substitute for skilled and attentive truck drivers. Drivers must be trained to handle pallet trucks and forklifts with precision, ensuring minimal contact with the racking structure. If a driver consistently makes contact with the racking, retraining is a crucial step to improve safety and reduce damage.
Future-Proofing Your Warehouse Racking
Investing in high-quality pallet protection is a proactive step toward creating a safer working environment. However, regular inspections and maintenance are equally important. Inspect all upright protectors, footplates, and floor fixings periodically to ensure they remain in optimal condition. Address any signs of damage immediately to prevent further issues.
For areas with particularly high activity levels, consider installing advanced protective solutions such as energy-absorbing barriers or impact-resistant materials. These can provide an additional layer of safety, particularly in warehouses with heavy equipment and constant movement.
Conclusion
Pallet racking protection is a vital aspect of warehouse safety and efficiency. By implementing suitable upright protectors, high-visibility guards, and robust end-of-row solutions, you can significantly reduce the risk of damage and ensure a safer working environment. Always prioritise quality over convenience when selecting protection solutions and conduct regular risk assessments to adapt to changing needs.
Please get in touch if you have any enquiries about your racking and we'll be happy to assist!