Pallet rack protectors are steel or plastic guards that take forklift hits so your upright columns don’t. The four main types are column (post) protectors, end-of-aisle guards, guard rails and bollards, and each one belongs in a different spot. This post covers which pallet rack guards to use where, how to install them, why a guard should never go on a damaged upright, and what protection costs next to a replacement frame, from a Connecticut dealer that stocks new and used rack protectors on its Plantsville yard.
What Are Pallet Rack Protectors?
Pallet rack protectors are impact guards mounted on or next to rack uprights to absorb or deflect forklift strikes before they bend a column. Most rack damage happens in the bottom few feet of the front upright, right where forks and mast legs pass during every pick.
The Rack Manufacturers Institute describes two broad approaches: guards attached directly to the column with bolts, rivets or straps, and freestanding guards such as bollards and guard rails anchored to the floor a short distance from the rack (RMI on protective guarding). Attached guards protect one column. Freestanding guards protect a whole row end or run of frames and keep the impact load out of the rack entirely.
Which Types of Pallet Rack Guards Should You Use?
Match the guard to the traffic. Column protectors handle everyday bumps along the aisle, end-of-aisle guards handle forklifts turning corners, and guard rails and bollards handle the heaviest traffic where trucks travel at speed.
| Guard type | Where it goes | What it protects against | Examples on the A&A yard |
|---|---|---|---|
| Column (post) protectors | Base of aisle-facing uprights | Fork tips and pallet corners striking the front column | New 12-inch protectors for 3-inch columns (up to 3 1/4 inch); used Mecalux HD 6 x 16 inch protectors for oversize footplates |
| End-of-aisle guards | Across the end frame of each row | Forklifts cutting the corner on a turn | Used Wildeck half-moon guards, 12 inches tall x 48 inches long, 1/2 inch thick (single- and double-sided) |
| Guard rails | Floor-anchored along long runs and walkways | Repeated side impacts along a row or a pedestrian lane | Used single- and double-rail guard rail, 18-inch posts, rails from 40 to 116 inches |
| Bollards | Row ends, dock edges, building columns | Direct hits from heavy or speeding trucks | Used 24-inch bollards |
Snap-on plastic and foam wraps are the light-duty end of the range. They help with scuffs from pallet jacks but won’t stop a loaded forklift.
What Size Rack Protector Do You Need?
Size the protector to the column face and the footplate, then to the traffic. A guard that doesn’t fit the column sits loose and does little when it’s hit.
- Column width. Measure the face of the upright. Standard teardrop uprights are commonly 3 inches wide, and protectors are sold by the column width they fit.
- Footplate size. Oversize or seismic footplates need a wider guard. The used Mecalux HD protectors on our yard are 6 inches wide for that reason.
- Height. 12-inch protectors cover the zone fork tips usually hit. Taller guards help where pallet jacks and mast legs strike higher on the column.
- Truck weight. Plastic wraps suit pallet jacks. Loaded counterbalance forklifts call for anchored steel guards, rails or bollards.
If you’re unsure, send a photo of the base of an upright with a tape measure across the column face. That’s enough to match a protector to your rack.
Where Should Rack Protectors Go First?
Start with the end-of-aisle uprights. Those columns take the most hits, since every forklift entering or leaving an aisle turns past them, and RMI notes that row ends are where traffic is heaviest.
After the row ends, work through this order:
- Uprights next to cross aisles and tunnels, where trucks pass the rack at an angle
- Racks nearest the dock, where drivers move fastest and visibility is worst
- Columns with a history of hits. Scuffed paint and bent base plates show you where operators are clipping steel
- Every aisle-facing upright in narrow aisles or high-turnover pick zones
Walk the floor with your supervisor and look for fresh paint scrapes at fork height. They tell you more than any layout drawing.
Can You Put a Rack Protector on a Damaged Upright?
No. Only undamaged columns should get a guard. MHI’s protective guarding group warns that most column protectors hide existing damage and mislead inspectors and users into believing the rack is safe (ProGMA FAQ).
Check every upright before guarding it. A crease, a dent in the column face, a bent brace or a splayed base plate means that frame gets unloaded and replaced first. Straightening a bent column in place is not a repair.
How Do You Install Column Protectors?
Install column protectors to the manufacturer’s instructions, on a clean, undamaged upright, anchored to the floor where the design calls for it.
- Measure the column. Note the column face width and the footplate size. A guard sized for a 3-inch column won’t fit over an oversize footplate.
- Inspect the upright. Confirm there’s no damage hiding under where the guard will sit.
- Set the guard. Position it tight to the aisle face of the column without lifting or shifting the base plate.
- Anchor it. Floor-mounted guards anchor to the slab, not into the rack. Use the anchors the guard maker specifies.
- Place freestanding guards with care. Bollards and guard rails go as close to the rack as possible without touching it, so a hit never transfers into the frame.
If you’re setting up a new system, plan guards into the layout from the start. Our step-by-step guide to installing warehouse racking covers where they fit in the sequence, and the post on anchoring your racks covers slab and anchor issues that apply to guards too.
Are Pallet Rack Protectors Worth the Cost?
Yes, in most warehouses a protector costs less than the first upright it saves. A used upright frame runs about $50 to $130 depending on height, and the frame is the cheap part.
Replacing a struck upright means unloading every pallet in the bays on both sides, removing beams, swapping the frame, re-anchoring and reloading. That’s lift time, labor and lost picks on top of the steel. A collapse costs far more. Used guards from the A&A yard sell well below new; a new Wildeck end-of-aisle guard like the ones we stock used costs over $200 each.
Guards make inspections easier to pass. RMI recommends quarterly inspections in high-traffic areas and an immediate one after any forklift impact (RMI inspection guidance). Fewer hits means fewer frames flagged on each walk.
Frequently Asked Questions
What is the difference between rack guards and rack protectors?
The terms overlap. “Rack protectors” usually means guards fastened to a single upright, such as column or post protectors. “Rack guards” often refers to larger floor-anchored pieces like end-of-aisle guards and guard rails that shield a row end or a run of frames.
Do pallet rack protectors need to be anchored to the floor?
Most heavy-duty column, end-of-aisle and rail guards are anchored to the slab so the impact goes into the floor instead of the rack. Light snap-on wraps attach to the column only. Follow the guard manufacturer’s anchoring instructions.
Does OSHA require pallet rack protectors?
OSHA has no rule that names rack protectors. Employers are still responsible for keeping storage stable and free of recognized hazards, and a struck upright is one. Guarding high-traffic columns is how most warehouses prevent that damage.
Can I buy used pallet rack protectors?
Yes. Used steel guards hold up well if they’re straight and the anchor holes are intact. A&A Surplus stocks used column protectors, end-of-aisle guards, guard rail and bollards in Plantsville, Connecticut, alongside new post protectors.
Find Rack Protectors at the Plantsville Yard
Browse current new and used post protectors and guards, or send a photo of your uprights and column width and we’ll match a guard to it. If your frames are already damaged, we can quote replacement uprights and send our installation services crew to swap them.
389 Marion Ave, Plantsville, CT 06479. Call 1-800-826-5326.