1. Understanding warehouse racking protection | The basics 

If you’re unfamiliar with warehouse racking and the protection it needs, then this section covers some of the most common questions.  

What is warehouse racking?

Warehouse racking refers to the system of shelves, racks, and storage structures used in warehouses and distribution centres to organise and store goods. Racking is usually made from steel with a painted or powder-coated finish.

Racking systems are designed to maximise storage space, improve accessibility, and facilitate efficient inventory management. There are various types of heavy-duty pallet racking, such as selective racks, drive-in racks, push-back racks, and pallet flow racks, each serving specific storage needs and load capacities. Warehouse racking plays a crucial role in optimising space and enhancing overall warehouse operations. 

Which industries use warehouse racking? 

There are a range of industries, sectors and businesses that use warehouse racking in their daily routines, including: 

• Warehousing and Distribution 
• Logistics 
• Manufacturing 
• Industrial Storage 
• Food and drink 

 

What types of facilities have warehouse racking?

Although the name refers to ‘warehouses’, racking is common across a variety of facilities, including: 

• Warehouses 
• Distribution centres 
• Storage Facilities 
• Cold storage facilities 

 

Each facility will present its own problems and hazards, so it is important to undertake a thorough risk assessment to understand what challenges you face when protecting your site.  

What is warehouse racking protection? 

Warehouse racking protection refers to safety systems that are used to protect vulnerable shelving and rack structures in busy warehouses. These items are used to provide additional shielding for areas of the racking that are most susceptible to potential collisions from industrial vehicles. 

Industrial vehicles might include: 

• Forklift trucks 
• Side loaders 
• Pallet trucks 
• Various materials handling vehicles and equipment 

 

Types of racking protection

When we talk about warehouse racking protection, we’re not referring to one type of product. There are a range of safety systems available to help protect racking from the hazards and risks present at busy facilities.  

These include: 

Rack leg protectors 
Rack Guards are cost-effective pallet racking protectors. They are an easy-to-install solution to protect rack uprights.

Rack end barriers 
Positioned at the end of racking isles to protect from impacts. RackEnd protective barriers are available in a range of sizes to suit your facility. They are also available in heavy-duty versions to protect from heavier industrial trucks.

Kerb barriers 
Provide racking protection at ground level and protection from fork impacts.

Racking monitoring systems 
Provide real-time impact alerts and identify impact hot spots

2. Warehouse racking hazards | What is at risk?

Racking protection is designed to protect vulnerable areas of industrial shelving. But what are the various risks and hazards that could be present at busy warehousing facilities? 

Why does warehouse racking need protection?

It is vital to ensure warehouse racking is safely defended for several reasons, including protecting: 

• People on site 
• Stock 
• Infrastructure  
• Keeping costs low 

 

If racking is impacted by a site vehicle it immediately creates potential issues. The racking itself could become damaged or weakened, in extreme situations, this could cause the racking to fail. 

If this happens then it is very likely that large volumes of stock, and the racking itself, could come crashing down. This will render the valuable stock unusable, at great cost to the business and customers. It could also potentially harm nearby workers and even cause damage to infrastructure or machinery.  

This could result in money loss for the business, including: 

• Replacing destroyed stock 
• Replacing/repairing racking and infrastructure 
• Production downtime while substantial repairs are made 
• Legal costs of accidents and injuries occurring on site 

 

However, racking collapses are very rare occurrences. In the event of a collision, It is more likely that racking will have to be quarantined. This is where all stock and goods are removed from the racking until it can be repaired or replaced.  

This can have a huge impact on daily operations. It can affect the amount of stock a warehouse can store at any one time and potentially make it impossible to fulfil orders on time. 

What are the hazards at a warehouse facility?

The risks to warehouse racking include:  

• Vehicles striking racking while loading/unloading stock 
• Forklift forks puncturing stock or denting racking 
• Vehicles catching rack ends while turning into a racking aisle 
• Minor scrapes and bumps which weaken racking over time 
• Racking collapses 

 

However, more general hazards faced at warehouses include: 

• Vehicle impacts with personnel 
• Goods falling from racking onto vehicles and workers 
• Topple accidents involving goods that have been stacked  
• Falling accidents involving people working at height or at loading docks 
• Damage to the building and infrastructure 

 

To combat these risks, it’s important to invest in the right kind of safety systems. In the next section, we will discuss the various types of warehouse racking protection.  

How do I know which racking protection I need for my warehouse?

When purchasing racking protection, it’s vital to understand the hazards that are present at your facility. By understanding the risks, you can better identify the types of protection you need.  

By using a combination of racking protection products, you can significantly increase the safety of your racking. While your facility may only need one or two types of protection, investing in all available options will greatly minimise the damage caused in case of a collision.

Warehouse rack damage can cause serious problems for any industry, especially distribution and logistics companies. Stay ahead of any hazards by investing in the correct safety systems. A-SAFE safety barriers and rack protectors are designed to provide the ultimate protection. Speak to one of our safety experts to find out more.  

3. Warehouse racking safety standards | What are the regulations?

Safety standards and regulations provide crucial guidelines for improving safety at industrial facilities. While not all of them are required by law, it’s useful to understand what guidelines exist in order to ensure your site safety measures are as effective as possible. 

Are there safety standards for warehouse racking protection?

Warehouse racking protection doesn't have specific safety standards, but the Health and Safety Executive (HSE) offers guidelines to keep workers safe. The HSE is a government branch that regulates health and safety, and its website is a valuable resource for improving site safety.

The HSE have provided a thorough Guide to Warehousing and Storage which includes sections on materials handling and storage areas. The regulations are not required by law, but they show the best way to keep your warehouse racking safe. If companies don't follow these guidelines and an accident happens due to poor maintenance or neglecting a known issue, they could be held responsible for their actions.

What are the HSE guidelines on warehousing and storage?

The HSE guidelines specifically apply to health and safety around warehouse racking than specific approaches to protection. However, it does provide a detailed guide to the best way to ensure you warehouse is properly installed and inspected at regular intervals.  

The guidelines cover a range of subjects, including: 

• Planning the layout of your warehouse and its racking at the same time 
• Ensuring your racking is installed properly 
• Prohibiting the misuse of racking – i.e. no overloading, no climbing, etc.  
• Providing proper physical protection 
• Ensuring racking is always highly visible to site drivers 
• Undertake regular rack inspections internally and with accredited external inspectors 
• Provide the necessary racking inspection training for designated personnel 

 

Warehouse racking protection | A summary

When protecting warehouse racking, it’s important to understand not only the risks you face at your facility, but also the regulations surrounding racking and the different types of protection available. With a little research and a thorough review of your site, you can arm yourself with the information you need to make an informed choice   

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