Rack Armour - Racking Protection

Rack Armour is a highly visible polymer upright protector manufactured from low-maintenance high-density polyethylene (HDPE), designed to protect exposed pallet racking uprights from damage caused by forklifts and material handling equipment operating within warehouse aisles.

Installed directly onto pallet racking uprights, the protector provides a durable external shell that absorbs and deflects impact energy from low-level vehicle contact. This helps prevent structural damage to the racking upright, reducing repair costs and minimising disruption to warehouse operations.

The high-visibility design improves the visibility of pallet racking structures within busy warehouse environments, assisting forklift operators in identifying rack locations and aisle boundaries. Rack Armour guards are available in a range of bright, easily detectable colours, including traffic-light style colour options that support warehouse safety and operational awareness.

Unlike steel protection systems, the polymer construction provides controlled impact absorption while remaining lightweight, corrosion resistant and easy to install.

Material and Construction

Rack Armour guards are manufactured from high-density polyethylene (HDPE), a durable polymer material selected for its strength, flexibility and resistance to industrial environments.

Material characteristics include:

• High-density polyethylene (HDPE) construction
• Resistant to water, mould, corrosion and most solvents
• Durable polymer structure designed to deflect and absorb impact
• Non-toxic and fully recyclable material
• Low-maintenance surface requiring no painting or coating

The polymer shell design protects the base of pallet racking uprights where most forklift impacts typically occur, helping maintain the structural integrity of the racking system.

Rack Armour guards are suitable for use in ambient, chilled and freezer environments, supporting installation within food production facilities, cold storage warehouses and temperature-controlled distribution centres.

Design and Installation

Rack Armour features a patented design that allows the guard to deflect and absorb impact energy while maintaining a secure fit around the racking upright.

Installation features include:

• Patented impact-deflecting design
• No fixings or mechanical fasteners required
• Guards can be fitted in seconds
• Transferable between racking uprights
• Multiple size options available to suit different racking profiles

The clip-on installation method allows the protector to be quickly installed or relocated as warehouse layouts change, making it a practical solution for evolving storage environments.

Multiple size variants are available to ensure a secure fit across common pallet racking systems, including Euro A, B, C, D and E upright profiles.

Visibility and Safety

Rack Armour guards are available in a range of highly visible colours designed to increase the visibility of pallet racking structures within warehouse environments.

Available colour options include:

• Hi-Vis Yellow
• Safety Yellow
• Bespoke colours available on request (minimum quantities may apply)

The high-visibility colour options help forklift operators identify racking locations quickly, reducing the likelihood of accidental impact within busy storage aisles.

Testing and Performance

Rack Armour has been tested to international standards including FEM 10.2.02, which relates to the protection of pallet racking structures within warehouse environments.

Testing demonstrated that Rack Armour guards protected the racking upright from noticeable structural damage when subjected to impacts typical of material handling equipment operating within racking aisles.

This performance confirms the protector’s ability to reduce the likelihood of racking damage caused by everyday forklift movements within warehouse operations.

Further testing information is available upon request.

Functional Benefits

• Protects pallet racking uprights from forklift impact
• Reduces risk of structural racking damage
• Patented impact-deflecting design
• Quick installation with no additional fixings required
• Transferable between racking uprights
• Highly visible colours improve racking visibility
• Suitable for ambient, chilled and freezer environments
• Fully recyclable, non-toxic polymer construction
• Low maintenance compared to steel protection systems

Typical Applications

Rack Armour is commonly specified for:

• Warehouse pallet racking aisles
• Distribution centres and logistics hubs
• Food production and storage facilities
• Cold storage and freezer warehouses
• Manufacturing and industrial storage areas
• Retail distribution warehouses
• High-traffic forklift operating environments

The protector is particularly effective in warehouse aisles where forklift trucks operate close to pallet racking structures.