Rack Armour

The Pallet Racking Protection Standard for UK Warehouses

Rack Armour® is the UK's most recognised name in clip-on pallet racking protection. Used across distribution centres, manufacturing plants, cold storage facilities, third-party logistics sites, builders' merchants, automotive warehousing, and food and beverage operations, Rack Armour® protects the most vulnerable part of any pallet racking system — the lower section of the upright leg, where forklift and MHE impacts cause the bulk of all racking damage.

Hall-Fast supplies the full authentic Rack Armour® range across all five upright sizes (Euro A through Euro E) and both standard finishes (Hi-Vis Yellow and Safety Yellow), along with the matching installation tools for site-wide rollouts. Every product is the genuine Rack Armour® article, independently tested to FEM 10.2.16, backed by our price match promise and supported by project-level bulk pricing for site-wide and multi-site orders.

Why Specify Rack Armour® Over Steel Column Guards

Traditional steel rack protectors don't really protect — on impact, they transfer the force into the racking upright or rip out their floor anchors, often making the damage worse. Rack Armour® works on the opposite principle: the patented HDPE outer shell deflects the impact while the high-density foam core absorbs the energy, before any of it reaches the racking leg. Independent testing shows an 80% reduction in racking damage compared with unprotected uprights.

The benefits extend beyond impact performance. Rack Armour® clips on by hand without floor fixings, which means no contractors, no drilling, no compromise to floor flatness specifications, and no operational disruption during fitting. It lifts off in seconds for the rack inspections required under FEM and HSE guidance. It performs at temperatures down to -40°C, resists corrosion and most industrial solvents, and has a 15+ year service life — typically absorbing multiple impacts before any replacement is needed.

The Rack Armour® Range Stocked at Hall-Fast

The Rack Armour® upright protector is available in five sizes to fit all standard UK pallet racking profiles, in two colour finishes for different site standards. All sizes share the same 600mm height, the same patented HDPE-and-foam construction, and the same 80% damage-reduction performance.

Upright Protectors – Hi-Vis Yellow

For brighter, more fluorescent visibility — best suited to cold stores, dim picking aisles, and any zone where the protector should function as an active visual cue beyond its impact role.

• Small (Euro A) — fits uprights up to 87mm wide → [Product page]
• Medium (Euro B) — fits uprights up to 100mm wide → [Product page]
• Large (Euro C) — fits uprights up to 110mm wide → [Product page]
• XL (Euro D) — fits uprights up to 120mm wide → [Product page]
• XXL (Euro E) — fits uprights up to 135mm wide → [Product page]

Upright Protectors – Safety Yellow

For the standard industrial Safety Yellow that integrates with existing bollards, kerb protection, and floor markings — the typical specification for site-wide rollouts and audited facility environments.

• Small (Euro A) — fits uprights up to 87mm wide → [Product page]
• Medium (Euro B) — fits uprights up to 100mm wide → [Product page]
• Large (Euro C) — fits uprights up to 110mm wide → [Product page]
• XL (Euro D) — fits uprights up to 120mm wide → [Product page]
• XXL (Euro E) — fits uprights up to 135mm wide → [Product page]

Installation Tools

For project installs and site-wide rollouts, the matching fitting tools dramatically reduce installation time and installer strain.

• Small to Medium Installation Tool (HFRACKAR12) — for Euro A and Euro B protectors → [Product page]
• Large to XXL Installation Tool (HFRACKAR11) — for Euro C, D, and E protectors → [Product page]

Which Size Do I Need? Quick Sizing Guide

The right size is determined by the front-facing width of your racking upright, measured in millimetres.

If your uprights are wider than 135mm, contact us with your racking specification — we can advise on the right protection approach.

Hi-Vis Yellow or Safety Yellow? Quick Colour Guide

Both colours deliver identical impact protection. The choice is about how the protector integrates visually into your site.

Choose Safety Yellow if:

• Your warehouse already uses standard industrial Safety Yellow on bollards, kerb protection, and floor marking
• You're rolling out across a multi-site network and need one specification that works in every building
• Your facility operates under an audit regime (BRC, ISO, customer SLAs) with written safety-colour standards
• The racking sits in well-lit ambient or covered conditions (steel stockholders, builders' merchants, automotive parts, agricultural storage)

Choose Hi-Vis Yellow if:

• The racking is in a cold or frozen storage environment with low ambient lighting
• The installation is VNA, shuttle, drive-in, or deep-lane racking where drivers need stronger visual cues
• You want the protection to function as an active high-visibility warning beyond its impact role

Many sites specify both: Safety Yellow as the building standard, with Hi-Vis as a zone-specific exception for cold stores and dim aisles. We can quote both finishes within a single project order.

Why Buy Rack Armour® from Hall-Fast

We're a UK-based industrial supplier with the full authentic Rack Armour® range stocked and ready to ship. Buying from Hall-Fast comes with:

• Price Match Promise. We won't be beaten on price for any authentic Rack Armour® product. Send us a lower online price or a written quote and we'll match it.
• Bulk and Project Pricing. Site-wide rollouts and multi-site projects qualify for volume pricing beyond the standard catalogue rate. Get in touch with your specification and quantities for a project quote.
• Full Range Available. All five sizes, both colours, and both installation tools — no gaps in the range, no waiting for special orders.
• Custom Branded Labels. By default Rack Armour® ships with plain branded labels. Add a request to order notes or contact us for custom company branding on project orders.
• UK Industrial Supplier. Hall-Fast is a long-established UK industrial supplies business. Talk to a real person about your specification — we're not a drop-shipper.
• Compliance Documentation. Rack Armour® is independently tested to FEM 10.2.16 and we can provide product specifications and test data to support your H&S, audit, or insurance documentation.

Where Rack Armour® Is Used

Rack Armour® is specified across virtually every industry that runs pallet racking, including:

• Distribution and fulfilment centres — high-traffic aisles, mixed MHE, frequent forklift impacts
• Cold and frozen storage — performs to -40°C, suitable for chilled and freezer warehouses
• Manufacturing and engineering stores — heavy loads, repetitive operations, demanding environments
• Third-party logistics (3PL) — multi-client sites with varied racking and continuous operations
• Beverage, FMCG, and food storage — heavy pallet weights, hygiene-critical environments
• Automotive parts and tyre warehousing — high-value stock, strict audit regimes
• Builders' merchants and steel stockholders — heavy-duty racking, covered yard installations
• Agricultural feed and grain stores — robust rural and industrial conditions
• Retail and wholesale back-of-house — picking faces, lighter-duty racking, archive storage

If you have racking and forklifts (or any powered MHE) operating near it, Rack Armour® is specified for your environment.

Project and Site-Wide Rollouts

If you're protecting more than a handful of uprights, talk to us about a project order. We routinely handle:

• Single-site rollouts covering hundreds of uprights across mixed sizes
• Multi-site network rollouts for retail DC portfolios, 3PL operations, FMCG distribution networks, and similar
• Phased delivery to multiple addresses or scheduled across a project timeline
• Combined orders covering protectors, installation tools, and complementary safety products
• Custom branded labelling at scale
• Bespoke quotes for non-standard upright sizes (above 135mm)

What is Rack Armour®? Rack Armour® is a clip-on pallet racking upright protector made from high-density polyethylene (HDPE) with an energy-absorbing foam core. It protects the lower section of racking uprights from forklift and MHE impacts, achieving an independently verified 80% reduction in racking damage. Unlike steel column guards, it absorbs and dissipates impact energy rather than transferring it into the racking leg or floor.

What sizes does Rack Armour® come in? Rack Armour® is available in five sizes covering uprights from up to 87mm wide (Small / Euro A) through to up to 135mm wide (XXL / Euro E). All sizes are 600mm tall. See the sizing guide above to identify the right size for your racking.

What's the difference between Hi-Vis Yellow and Safety Yellow Rack Armour®? The protective performance is identical — both colours use the same HDPE shell, foam core, and patented design. The difference is the visual finish. Safety Yellow is the classic industrial warning yellow that matches most existing warehouse bollards, kerb protection, and floor markings. Hi-Vis Yellow is brighter and more fluorescent, better suited to lower-light environments like cold stores and dim picking aisles. Many sites specify both, with Safety Yellow as the building standard and Hi-Vis as a zone-specific exception.

Is Rack Armour® better than steel rack protectors? For most applications, yes. Steel column guards transfer impact force into the racking leg or rip out their floor anchors on impact. Rack Armour® absorbs and dissipates the impact energy, won't rust or deform, and lifts off easily for the rack inspections required under FEM and HSE guidance. It also requires no floor fixings, which avoids damage to the warehouse floor and removes the need for contractor installation.

Is Rack Armour® FEM tested? Yes. Rack Armour® has been independently tested to FEM 10.2.16, the European standard for racking impact protection. This supports compliance with current warehouse safety best practice and demonstrates due diligence under HSE guidance.

Does Rack Armour® work in cold storage? Yes. Rack Armour® is rated to operate at temperatures down to -40°C, suitable for ambient, chilled, and frozen storage environments. For very low-light cold storage, the Hi-Vis Yellow finish is often preferred.

How long does Rack Armour® last? Rack Armour® has a 15+ year design life and absorbs multiple impacts before needing replacement, depending on the force of each strike. Across that lifespan, the cost per upright per year of protection is typically a fraction of a single rack repair.

Do I need contractors to install Rack Armour®? No. One of Rack Armour®'s key advantages is that it clips on by hand without bolts, anchors, drilling, or floor fixings. Most warehouses install it with their own facilities team or maintenance staff. For larger site-wide rollouts, the matching installation tools speed up fitting significantly — we stock both the Small/Medium and Large/XL/XXL versions.

Do you offer bulk and project pricing? Yes. Hall-Fast offers volume pricing on Rack Armour® for site-wide rollouts, multi-site projects, and high-volume orders. Contact our sales team with your specification and quantities for a project quote.

Do you really price match? Yes — our price promise covers every authentic Rack Armour® product across the full range. Send us a lower online price or a written quote and we'll match it.

Can I get my company branding on the protectors? Yes. Rack Armour® ships with plain branded labels by default. Add a note at checkout if you'd like your company details printed on the labels, or contact us directly for branded labelling on project-scale orders.

My uprights are wider than 135mm — what should I do? 135mm (Euro E / XXL) is the largest size in the standard Rack Armour® range. If your uprights are wider, contact us with your racking specification and we'll advise on the right protection approach for your installation.