Rack Armour® XL Upright Racking Protectors - Hi Vis Yellow

Engineered Protection for Heavy-Duty Racking Uprights

Some racking carries more risk than others. Drive-in systems, high-bay racking, beverage and FMCG storage, and any racking holding heavy or high-value pallets all share one thing in common — a damaged upright in the wrong place can take a full bay, an aisle, or in the worst case a whole run of racking out of action. The Rack Armour® XL Upright Racking Protector is built for these environments, sized to fit front-facing uprights up to 120mm wide (Euro D).

Standing 600mm tall in high-visibility yellow, the XL protector clips onto the upright by hand in seconds. The patented HDPE outer shell deflects forklift impacts and the high-density foam core absorbs the energy before it can reach the racking leg, achieving an independently verified 80% reduction in racking damage — the same proven Rack Armour® performance, scaled up to fit larger industrial racking profiles.

Our Price Promise: We won't be beaten on price for any authentic Rack Armour® product. Send us a lower online price or written quotation and we'll match it.

Why It Outperforms Heavy Steel Column Guards

On heavy-duty racking, the temptation is to specify steel column guards because they look more substantial. The reality is that bigger steel guards transfer bigger forces — straight into the racking upright or out through the floor anchors. Rack Armour® does the opposite:

• Absorbs and dissipates impact energy instead of passing it through the upright
• No floor fixings required — clips on by hand without anchors, drilling, or floor damage
• Won't deform, rust, or split the way welded steel guards do
• Lifts off easily for the racking inspections required under FEM and HSE guidance
• Independently tested to FEM 10.2.16

Performs Where Other Protection Fails

Larger racking installations are often in the harshest warehouse environments — chilled and frozen distribution, busy 3PL operations, automotive parts distribution, drinks logistics, and heavy manufacturing. Rack Armour® XL is rated to -40°C, resistant to moisture, corrosion, and most industrial solvents, and built for repeat impact resistance over a 15+ year service life. One fitment typically protects the upright through multiple strikes before any replacement is needed.

Key Features

• Patented HDPE outer shell with high-density energy-absorbing foam core
• Independently verified 80% reduction in racking damage
• Sized for heavy-duty uprights up to 120mm wide (Euro D)
• 600mm height — covers the strike zone where forklift damage occurs
• Hi-vis yellow finish for clear MHE driver awareness
• Tool-free clip-on installation — no anchors, no drilling
• Tight grip stays on after impact
• Operating range down to -40°C
• Tested to FEM 10.2.16
• 15+ year design life
• Custom branded labels available — add request to order notes at checkout

Specifications

Where the XL (Euro D) Size Fits

Euro D 120mm uprights are typical of heavy-duty industrial racking. You'll find them on drive-in and drive-through racking, high-bay pallet racking in larger distribution centres, beverage and FMCG storage where pallets are heavy and turnover is high, automotive parts warehouses, cold and chilled stores running larger MHE, and bespoke heavy-load systems in manufacturing. They're also used in narrow-aisle and very-narrow-aisle (VNA) installations where a single upright impact can have outsized consequences for stock isolation and bay availability.

If you're not sure whether you need Euro C or Euro D, measure the front-facing width of the upright in millimetres: above 110mm and up to 120mm sits in the XL bracket.

Protect High-Value Bays Before the Next Impact

The cost of replacing an XL-sized upright isn't just the steel — it's the bay you have to evacuate, the stock you have to relocate, the inspection contractor you have to bring in, and the pick faces you have to reroute around while the work is done. Rack Armour® XL Upright Protectors clip on in seconds and start absorbing impacts from the next forklift strike onwards. Add to your order today and take advantage of our price match promise on every authentic Rack Armour® product.

What size pallet racking does the XL Rack Armour® protector fit? The XL (Euro D) size fits front-facing uprights from above 110mm and up to 120mm wide. This covers heavier-duty industrial racking profiles used in drive-in racking, high-bay systems, and other heavy-load applications.

How do I choose between Euro C (Large) and Euro D (XL)? Measure the front-facing width of your racking upright. Above 100mm and up to 110mm = Euro C / Large. Above 110mm and up to 120mm = Euro D / XL. If your uprights are wider than 120mm, the Rack Armour® range also includes the Euro E size.

Is Rack Armour® suitable for drive-in racking? Yes. Drive-in racking is a particularly common Rack Armour® application because forklifts operate inside the rack run and impacts are statistically more frequent. The XL size is the typical fit for the heavier upright profiles used in drive-in systems.

Does it really clip on without floor fixings? Yes. Each Rack Armour® protector slides onto the upright and clips into place by hand. No anchors, drilling, or contractor visits are required, which is why it's the default choice for full-site rollouts and bay-by-bay phased installations.

How much damage does Rack Armour® prevent? Independent testing shows an 80% reduction in racking damage when Rack Armour® is fitted. The HDPE shell deflects the impact while the foam core absorbs the energy before it reaches the upright structure.

Will it work in cold storage and freezer environments? Yes. Rack Armour® is rated to operate at temperatures down to -40°C without loss of performance, suiting it to ambient, chilled, and frozen storage environments.

Is Rack Armour® FEM tested? Yes. The product has been independently tested to FEM 10.2.16, the European standard for racking impact protection, supporting compliance with current warehouse safety best practice.

How long does it last? The XL upright protector has a 15+ year design life and can absorb multiple impacts before needing replacement, depending on the force of each strike. Cost per year of protection works out to a few pence per upright per week on most installations.

Can I have 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 own company details printed on the label.

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