Should You Invest in Warehouse Rack Safety Guards?
Rack guards are simple and effective tools used in warehouses across the country. How do they work, what are the differences between the models, and should you invest in them?
Warehouses can be dangerous and hectic environments, and if you have a lot of forklift traffic, it’s important to make extra investments in protecting your pallet rack storage systems.
According to Mazzella’s Warehouse Solutions Specialists, over 90 percent of pallet rack damage is caused by forklifts and similar transportation devices. Companies make big investments to store their materials safely, and all it takes is a single forklift veering off to cause a major pallet rack collapse and put the lives of your workers at risk. So, what can your organization invest in to protect your racks, your products, and your workers.
If you have recently ventured into a warehouse, walking down the various aisles and bays, you have probably seen bright yellow plates at the base of pallet rack systems. These are called warehouse rack guards.
Are warehouse rack guards worth the investment, and which model is best suited for your needs? Mazzella has been a leader in the warehouse solutions space for years, partnering with reputable manufacturers. In that time, we have installed, quoted, and inspected countless warehouse rack guards, and we hope to answer your questions in this article. We will cover:
What are Warehouse Rack Safety Guards?
Warehouse rack guards, sometimes called frame protectors or end of aisle protectors, are protective structures installed on or around pallet racks to prevent or reduce damage from forklifts and other product handling vehicles. While a single forklift bump is common and not too concerning, this happening dozens— maybe hundreds—of times over several years could chip away at the rack’s structural integrity, increasing the chance of catastrophic failure.
Made from high-quality steel, rack guards can absorb contact from these vehicles and create a barrier around the pallet rack’s base. They can be bolted to the racking itself or bolted to the floor.
Where are Warehouse Rack Safety Guards Installed?
Rack guards are best suited for areas with high forklift traffic, but they can be useful wherever you use any type of storage system.
Rack guards can also be used in other applications. For example, ribbed barrier guardrails, also called stand guard guardrails, are great for protecting work cells, aisle ways, and temporary offices. Other guard models are designed for reducing wall damage as well.
Are Warehouse Rack Safety Guards an OSHA Requirement?
While there is no standard for specific equipment like warehouse rack safety guards, OSHA provides guidance through their General Duty Clause, and our specialists are seeing more facilities installing them to adhere to this safety clause.
This clause states that you need to provide a workplace free of recognized hazards by following updated ASME standards, ANSI standards, manufacturer recommendations, and the advice of industry leaders.
It’s good practice to stay up to date on the Rack Manufacturers Institute’s (RMI) standards and best practices, as OSHA will typically cite their standards under the General Duty Clause.
What are the Benefits of Warehouse Rack Guards?
There are multiple benefits in having rack safety guards at your facility. Some of the major ones are:
Extended Life for Pallet Racks
As mentioned in previous articles, the most common problem found during pallet rack inspections is damaged uprights and beams. Damaged uprights or cross beams directly affects the structural integrity of your rack, permanently compromising their load-carrying capacity.
Having that extra layer of protection can dramatically extend the life of your pallet racks and save you thousands of dollars by avoiding purchasing a new rack system.
Enhanced Safety for Workers
If a forklift operator bumps into a rack, it could create a domino effect with nearby racks, causing thousands of pounds of metal and products to fall on employees.
In addition to safety guard systems, your pallet racks should have:
- Wire decks
- Safety clips on the rack’s beams
- Anchors
- Proper capacity postings
Increased Protection for Stored Materials
There is no greater threat to your stored materials than a compromised pallet rack system. Equipping your racks with guards will increase the chance of your stored products being safe, even if a forklift slams into it. On top of rack guards, you can protect your materials by:
- Using properly sized rack members or system configurations
- Investing in well-performing material handling vehicles
- Properly training workers on how to load and unload material
Cost Savings
Rack guards are relatively inexpensive, especially compared to the cost of replacing an entire bay of pallet racks.
What are the Different Warehouse Rack Guard Models?
There are many rack guard models available. Some of the most common ones seen are:
Post Protectors
The most common rack guard model used in warehouses.
End of Ailse Guards
End of aisle safety guards are especially great for areas in with high forklift traffic.
Column Protectors
Guards can even be used to protect columns and walls in a warehouse.
Are There Any Cons to Warehouse Rack Guards?
While rack guards are relatively inexpensive and seemingly simple solutions, installing them is a time-consuming, labor-intensive endeavor, especially for large facilities with many bays and aisles. Installing them may require concrete anchors and specialized equipment.
Proper planning and coordination with your warehouse solution providers is important to reduce prolonged downtime and disruption to operations and can be especially challenging for high-traffic, 24/7 shipping facilities.
Before investing, you should consider:
- The size of your facility and how many bays / aisles need rack guards
- The budget you’re working with. Are you factoring installation costs?
- The building’s structure and floor specifications
- Time frame for completion
- Product flow and accessibility requirements
Inspecting Pallet Rack Safety Guards
During a third-party pallet rack inspection, inspectors will review the integrity of your rack guards. Rack protectors are inherently meant to take damage from forklifts, but you will want to make sure they stay properly anchored to the ground.
The life of any rack guard depends on the gauge of metal used in the guard then level and frequency of impact placed on the guard. Ideally, you hope to never have to replace a rack guard.
Why Should You Invest in Warehouse Rack Safety Guards?
While simple, warehouse rack guards are a crucial tool to improving warehouse safety and prolonging the life of your pallet racks.
We hope this article helped you learn more about their best use cases and the benefits of investing in them. If you decide to purchase rack guards, make sure to work with your installer to avoid excessive downtime. Mazzella has been a leader in the warehouse solutions industry for years, partnering with many premier warehouse rack guard manufacturers in the country. Contact a Warehouse Solutions team member to learn more.
Mazzella is also a leader in third-party pallet rack inspections. Schedule your inspection today, and watch our informative video with Marc Smith, Warehouse Solutions Specialists for Mazzella, walk us through what a third-party inspection looks like.
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