Is Investing in Pallet Racking Protection Worth It?

A Comprehensive Guide

What is Pallet Racking Protection and Why is It Necessary?

At Shelving Depot, we understand that some level of pallet racking protection is an important element in ensuring the safety and efficiency of warehouses. It involves a variety of safety measures and physical barriers designed specifically to safeguard pallet racking systems from damage caused by forklifts, machinery, or accidental impacts. These protective solutions are essential not only for preserving the structural integrity of the racking systems but also for promoting a safer work environment and reducing the risk of costly repairs or accidents.

Without proper protective elements in place, even minor incidents can lead to expensive damage and, in severe cases, cause complete racking failures. By incorporating the appropriate pallet racking protection, businesses can mitigate the risk of damage, extend the lifespan of their racking systems, and maintain a more productive and secure warehouse environment. 

Types of Pallet Racking Protection

The main types of pallet racking protection include post protectors, end-of-aisle protectors, and rack guards.

Post protectors are designed to shield the base of racking columns from impacts. Positioned at the bottom of the racking system, these post protectors absorb the force of collisions, often caused by forklifts, preventing damage to the racking’s support structure.

End-of-aisle protectors are placed at the end of pallet racking rows. These protectors are a cost-effective solution for high-traffic areas where forklifts frequently turn in and out of aisles. Given their low cost and high utility, end-of-aisle protectors are often recommended as an essential safety measure.

Rack guards attach to the front of racks and act as a visual and physical barrier, alerting forklift operators when they’ve come too close. While rack guards offer versatility and provide immediate operator awareness of a collision, they offer less protection than post protectors, which are bolted into the ground for a more rigid defence.

For larger warehouses or those with complex layouts, additional protection may be necessary. Bollards around pedestrian doors and behind workstations provide extra safety for workers moving through high-traffic areas.

Benefits of Pallet Racking Protection

The primary benefit of pallet racking protection is preventing damage to racking systems. These systems are designed to support heavy loads, and even small amounts of damage can compromise their stability. Protective elements act as a buffer between racking and potential sources of impact, reducing the likelihood of structural damage.

Pallet racking protection also enhances safety in the warehouse. By minimising the risk of accidents caused by racking collapses or displaced loads, businesses can create a safer working environment for their employees. In turn, this leads to fewer workplace accidents, less downtime for repairs, and a smoother flow of operations.

In New Zealand, with our high earthquake risk, compliance with WorkSafe safety standards is crucial for warehouse operations. Pallet racking protection, like safety backing or anti-collapse mesh, helps prevent pallets from falling during seismic events or impacts, safeguarding both workers and products. At Shelving Depot, we prioritise these protective measures to ensure your racking systems meet compliance and maintain safety in any conditions.

Another benefit of racking protection is the long-term cost savings associated with preventing damage. Without protection, damaged racking often needs to be isolated, unloaded, and repaired, which can disrupt productivity. By investing in protection upfront, businesses can avoid these costly delays and maintain operational efficiency.

Cost vs. Risk: Evaluating the Investment

When deciding whether to invest in pallet racking protection, it’s essential to weigh the cost against the potential risks. For most warehouses, protection typically adds about 8-10% to the overall cost of a fitout. While this might seem like a significant expense initially, the cost is minimal compared to the potential financial risks associated with unprotected racking.

Without proper protection, forklift-related damage is one of the most common causes of pallet racking failure. The impact of even a minor collision can result in expensive repairs and pose serious health and safety risks. Additionally, accidents can lead to downtime as damaged racks are repaired, further driving up costs. Considering these factors, pallet racking protection is a sound investment that reduces both financial risk and liability.

Long-Term Value: Extending the Lifespan of Pallet Racking Systems

Investing in protection for your pallet racking offers significant long-term value by extending the lifespan of the system. Regular maintenance and minor repairs are necessary, but protection minimises the extent of damage over time, reducing the frequency and cost of these interventions.

In larger warehouses, where more staff and machinery are involved, it can be difficult to track when and where damage occurs. By installing protective elements, businesses can lower the chances of unnoticed damage causing long-term issues. The costs of make-good repairs, which can average around $1500 per year for a 1,000-square-metre facility, are significantly reduced when protection is in place.

For companies concerned with long-term budgeting, pallet racking protection demonstrates proactive risk management, ensuring that the racking system remains functional and safe for years to come. Additionally, businesses that invest in these protective measures show a commitment to safety, reducing the liability for managers and directors by actively protecting their staff and assets.

Is Pallet Racking Protection Worth the Investment?

Whether pallet racking protection is a necessity depends on the scale and nature of the business. For larger warehouses, where more employees and machinery are in use, the risk of damage is higher, and the cost of lost productivity due to racking repairs can quickly add up. In these cases our advice is that pallet racking protection is not just a wise investment but a necessary one.

For businesses on the fence about investing in protection, end-of-aisle protectors are a good starting point. They offer high utility at a low cost, particularly in high-traffic areas. Companies that are looking to stretch their budget can also consider installing protection a few months after the initial racking fitout to spread costs, this is a strategy that has worked for many of our customers.

Ultimately, pallet racking protection provides both immediate and long-term benefits, from preventing accidents to extending the lifespan of your racking systems. For businesses looking to safeguard their assets, protect their employees, and ensure a more efficient operation, investing in pallet racking protection is a smart decision.

If you’re considering a pallet racking fitout or looking to enhance your current warehouse setup with additional protection, our team is here to help. Contact us today to discuss your needs and find the right protective solutions to ensure the safety and longevity of your racking system.