Choosing the right Rack Armour size is the single most important decision a specifier makes when deploying upright racking protection. The Rack Armour family covers five distinct sizes – Small, Medium, Large, XL and XXL – each engineered for a particular strike envelope and operating profile. Specify too small a unit and you leave a band of upright steel exposed above the protector. Specify too large a unit and you carry incremental cost without proportionate risk reduction. This complete Rack Armour size guide helps procurement, operations, facilities and safety teams across the UK make the right call for every upright in their estate.
We start by reviewing the strike profile of common UK warehouse MHE, then walk through every Rack Armour size in detail with its target use cases, technical characteristics and direct links to the corresponding product page at Hall-Fast Industrial Supplies. We follow this with guidance on building a mixed specification across a single site, on choosing between Hi-Vis Yellow and Safety Yellow finishes, on installation tooling, and on common procurement scenarios. Whether you are protecting a single aisle or rolling out across a national logistics estate, this guide brings every dimension of the size decision into one place.
Hall-Fast Industrial Supplies stocks the complete authentic Rack Armour range, supports specifiers with expert size advice and operates a price promise that guarantees the best available UK terms on every authentic Rack Armour purchase. To see all sizes side by side, the dedicated Rack Armour brand section at https://www.hall-fast.com/brands/rack-armour brings every product page into one navigable hub.
What Is Rack Armour and How Does It Work?
Rack Armour is a clip-on, polymer-shell upright protector engineered specifically to defend pallet racking uprights from forklift impact. The product consists of a moulded high-performance engineering polymer shell that wraps around the front and side faces of a racking upright at floor level. When a forklift truck, reach truck, pallet truck or similar piece of MHE strikes the upright, the polymer shell flexes under load, absorbing and dissipating impact energy across its body rather than transferring it directly into the rack steel.
The fundamental difference between Rack Armour and traditional steel guards is this energy-absorbing behaviour. A rigid steel guard transfers impact load into the upright and the floor anchor, often with the result that the guard, the upright or the slab around the anchor sustains visible damage. Rack Armour absorbs the strike, recovers its shape after most low and medium severity impacts, and protects the upright behind it from the strike profile of the incoming MHE.
Rack Armour is available in five sizes – Small, Medium, Large, XL and XXL – covering protection heights from approximately 300mm through to a comprehensive coverage zone for the heaviest MHE traffic. Each size is available in two finishes, Hi-Vis Yellow and Safety Yellow, with identical impact performance across both colour options. The product line is complemented by dedicated installation tools that ensure correct fit without stressing the polymer shell during deployment.
Mapping Forklift Strike Profiles to Protector Heights
The starting point for any size decision is the strike profile of the MHE operating on the site. Different machines present different chassis heights, fork carriage positions and mast profiles, and the right protector height is the one that covers the full strike envelope of the equipment in use.
Hand Pallet Trucks and Walk-Behind Stackers
Manual hand pallet trucks and walk-behind powered stackers present strike profiles concentrated in the lowest 200mm to 300mm of the upright. The fork heels, the chassis bumper and any rear corner are all in the lower zone. The 300mm Small Rack Armour is the natural size for these operations.
Low-Level Order Pickers
Low-level order pickers are designed for picking from the lowest beam levels and present strike profiles between 250mm and 400mm depending on chassis design and operator platform. The Small or Medium variants are typical specifications for these operations, with size choice driven by the specific machine in use.
Compact Reach Trucks and Small Counterbalance Forklifts
Compact reach trucks and small counterbalance forklifts running 1,000kg to 1,500kg payloads typically present strike envelopes from 200mm up to approximately 500mm, depending on chassis design and travelling fork height. The Medium or Large variants are well suited to these operations, with the Large variant often chosen for high-traffic locations.
Standard Counterbalance Forklifts and Reach Trucks
Standard 2,000kg to 3,000kg counterbalance forklifts and reach trucks present strike envelopes that comfortably reach 600mm. The 600mm XL is the default specification for facilities operating these machines at production cadence, particularly at aisle-end uprights and other high-traffic locations.
Large Counterbalance, Container Handlers and Drive-In Operations
Sites running heavy counterbalance trucks, container handlers, or drive-in racking with deep mast exposure can experience strike profiles above the XL coverage zone. The XXL variant is the right specification for these environments, providing the maximum coverage in the Rack Armour family.
The Full Rack Armour Size Range Explained
Specifying the right Rack Armour size for your operation depends on the strike profile of your MHE, the operating intensity of the site, and the budget envelope. Hall-Fast supplies all five sizes in both colour finishes, so specifiers can build a balanced deployment using the right size at the right location.
Small (Approximately 300mm)
The Small variant delivers approximately 300mm of vertical protection from floor level. It is best suited to operations dominated by pedestrian-operated MHE such as walk-behind powered pallet trucks, low-level order pickers and manual pallet trucks. Its low unit cost makes it a popular choice for blanket coverage of long, lower-risk rack runs.
Small Hi-Vis Yellow product page: https://www.hall-fast.com/brands/rack-armour/rack-armour-small-upright-racking-protectors-hi-vis-yellow
Small Safety Yellow product page: https://www.hall-fast.com/brands/rack-armour/rack-armour-small-upright-racking-protectors-safety-yellow
Medium
The Medium variant extends protection to suit slightly larger MHE and mixed operations. Sites running compact reach trucks alongside pedestrian equipment often choose Medium as a balanced specification, especially where the strike profile is not consistently above the small zone but does occasionally approach the upper limit of pedestrian-MHE strikes.
Medium Hi-Vis Yellow product page: https://www.hall-fast.com/brands/rack-armour/rack-armour-medium-upright-racking-protectors-hi-vis-yellow
Medium Safety Yellow product page: https://www.hall-fast.com/brands/rack-armour/rack-armour-medium-upright-racking-protectors-safety-yellow
Large
The Large variant is engineered for mainstream pallet operations using compact counterbalance trucks and standard reach trucks. It delivers comprehensive coverage of the typical mid-zone strike profile and is a default choice for many UK distribution centres.
Large Hi-Vis Yellow product page: https://www.hall-fast.com/brands/rack-armour/rack-armour-large-upright-racking-protectors-hi-vis-yellow
Large Safety Yellow product page: https://www.hall-fast.com/brands/rack-armour/rack-armour-large-upright-racking-protectors-safety-yellow
XL (Approximately 600mm)
The XL variant provides approximately 600mm of vertical protection, making it the workhorse of the range for high-throughput distribution centres, busy manufacturing line-side storage and general logistics operations. The 600mm height covers the full strike envelope of most counterbalance and reach truck contact.
XL Hi-Vis Yellow product page: https://www.hall-fast.com/brands/rack-armour/rack-armour-xl-upright-racking-protectors-hi-vis-yellow
XL Safety Yellow product page: https://www.hall-fast.com/brands/rack-armour/rack-armour-xl-upright-racking-protectors-safety-yellow
XXL
The XXL variant is engineered for the most demanding strike profiles, including tall counterbalance trucks, container handlers and drive-in racking with deep mast exposure. It is the right specification where the strike envelope reaches above the XL coverage zone or where a site has experienced repeated strikes near the top of an XL protector.
XXL Hi-Vis Yellow product page: https://www.hall-fast.com/brands/rack-armour/rack-armour-xxl-upright-racking-protectors-hi-vis-yellow
Hall-Fast Rack Armour Resources and Product Pages
Hall-Fast Industrial Supplies stocks the complete authentic Rack Armour range and provides a single point of purchase for every size, every colour and every installation accessory you may require. The links below take you directly to the individual product pages, where you can review specifications, request quantities and place orders for next-day despatch where stock allows.
Brand and Company Pages
· Rack Armour brand hub at Hall-Fast: https://www.hall-fast.com/brands/rack-armour
· About Hall-Fast Industrial Supplies: https://www.hall-fast.com/about
· View all brands stocked by Hall-Fast: https://www.hall-fast.com/brands
· Contact the Hall-Fast team: https://www.hall-fast.com/contact
Hi-Vis Yellow Rack Armour Products
· Rack Armour Small Upright Racking Protectors – Hi-Vis Yellow: https://www.hall-fast.com/brands/rack-armour/rack-armour-small-upright-racking-protectors-hi-vis-yellow
· Rack Armour Medium Upright Racking Protectors – Hi-Vis Yellow: https://www.hall-fast.com/brands/rack-armour/rack-armour-medium-upright-racking-protectors-hi-vis-yellow
· Rack Armour Large Upright Racking Protectors – Hi-Vis Yellow: https://www.hall-fast.com/brands/rack-armour/rack-armour-large-upright-racking-protectors-hi-vis-yellow
· Rack Armour XL Upright Racking Protectors – Hi-Vis Yellow: https://www.hall-fast.com/brands/rack-armour/rack-armour-xl-upright-racking-protectors-hi-vis-yellow
· Rack Armour XXL Upright Racking Protectors – Hi-Vis Yellow: https://www.hall-fast.com/brands/rack-armour/rack-armour-xxl-upright-racking-protectors-hi-vis-yellow
Safety Yellow Rack Armour Products
· Rack Armour Small Upright Racking Protectors – Safety Yellow: https://www.hall-fast.com/brands/rack-armour/rack-armour-small-upright-racking-protectors-safety-yellow
· Rack Armour Medium Upright Racking Protectors – Safety Yellow: https://www.hall-fast.com/brands/rack-armour/rack-armour-medium-upright-racking-protectors-safety-yellow
· Rack Armour Large Upright Racking Protectors – Safety Yellow: https://www.hall-fast.com/brands/rack-armour/rack-armour-large-upright-racking-protectors-safety-yellow
· Rack Armour XL Upright Racking Protectors – Safety Yellow: https://www.hall-fast.com/brands/rack-armour/rack-armour-xl-upright-racking-protectors-safety-yellow
Rack Armour Installation Tools
· Installation Tool for Small to Medium Rack Armour: https://www.hall-fast.com/brands/rack-armour/rack-armour-installation-tool-suitable-for-small-to-medium-rack-armour
· Installation Tool for Large to XL Rack Armour: https://www.hall-fast.com/brands/rack-armour/rack-armour-installation-tool-suitable-for-large-to-extra-large-rack-armour
Building a Mixed Specification: Most Sites Use More Than One Size
It is common – arguably best practice – for a single site to deploy more than one Rack Armour size. The right specification matches each upright to the strike profile and operating intensity at that location, rather than imposing a single size across an entire facility regardless of risk.
A Typical Three-Tier Specification
A common pattern across UK distribution centres uses three Rack Armour sizes. Aisle-end uprights and cross-aisle intersection columns are protected with the XL variant, providing 600mm of coverage at the highest-traffic locations. Picking-face uprights along the length of each aisle use the Small or Medium variant, providing focused protection of the dominant low-level pick-truck strike zone at a manageable unit count. Drive-through entries and any column with repeat damage history use the XXL variant, providing maximum coverage where the strike profile and consequences justify the upgrade.
Using the Hall-Fast Team to Validate the Mix
Specifying a mixed deployment is straightforward with Hall-Fast support. The team can review the layout drawings, the MHE profile and the inspection history and recommend a size mix that delivers the strongest risk reduction for the available budget. For multi-site programmes the team can support a consistent specification across all locations or tailor the mix site by site to local operating conditions.
Choosing Between Hi-Vis Yellow and Safety Yellow Finishes
Each size in the Rack Armour family is available in two finishes: Hi-Vis Yellow and Safety Yellow. The choice between the two is driven entirely by visibility needs and visual-standard alignment – impact performance is identical across both finishes.
Hi-Vis Yellow
Hi-Vis Yellow uses a fluorescent shade that delivers maximum visual contrast against dark racking, dark stock and low ambient light. The finish is particularly effective in low-bay rack shadow, in mixed-traffic environments, and where automated vehicles share aisles with pedestrian operatives. Hi-Vis Yellow is the strongest choice when visibility is the dominant priority.
Safety Yellow
Safety Yellow uses the traditional industrial yellow specified in many corporate H&S colour standards. It coordinates well with floor marking paint, bollards, hand rails, guarding and other site infrastructure already specified to the same shade. Safety Yellow is the right choice where corporate standards drive the colour decision and where the broader visual environment is consistent.
Mixing Finishes Within a Site
Most sites adopt a single finish for the whole estate to provide a clear visual standard. Some sites use Hi-Vis Yellow in lower-bay areas where visibility is the priority and Safety Yellow in showroom or customer-facing areas where visual coordination matters. Hall-Fast can support either approach with consolidated stock management.
Installing Rack Armour: A Fast, In-House Process
One of the most important commercial benefits of Rack Armour is the speed and simplicity of installation. The product clips onto a racking upright using a dedicated installation tool, with no welding, no drilling, no floor anchor and no curing time. Each unit is typically installed in well under a minute by a single trained operative, allowing large-scale deployments to be completed in hours or days rather than the weeks that contractor-led steel guard rollouts can require.
Hall-Fast supplies two installation tools matched to the size of the protector being fitted. The Small to Medium tool is sized for the lighter shells and is appropriate for the Small and Medium variants. The Large to XL tool is sized for the larger shells and is appropriate for the Large, XL and XXL variants. Investing in the correct tool for the size you are deploying ensures correct fit without stressing the polymer shell.
Installation Tool – Small to Medium: https://www.hall-fast.com/brands/rack-armour/rack-armour-installation-tool-suitable-for-small-to-medium-rack-armour
Installation Tool – Large to XL: https://www.hall-fast.com/brands/rack-armour/rack-armour-installation-tool-suitable-for-large-to-extra-large-rack-armour
Because installation requires no power tools and no anchoring, units can be fitted in a live warehouse without taking pallet positions out of service. Operatives only need to ensure a brief safe-working zone around the upright during fitting. This is in stark contrast to traditional steel guards, which often require pallet decanting, MEWP clearance for higher fixings and sometimes hot-work permits for welded installations.
Industries Where Rack Armour Is Widely Used
Rack Armour is deployed across virtually every sector that uses pallet racking. The strike risks are common across sectors, and the product is engineered to be robust enough for the most demanding environments while still cost-effective for lighter applications.
FMCG and Consumer Goods Distribution
High-throughput FMCG distribution centres are a core use case. The combination of high MHE traffic, tight aisle geometries and consequence-heavy stock makes the case for protection compelling, and the rapid in-house installation process suits FMCG operating tempos.
E-commerce and 3PL Operations
E-commerce fulfilment and 3PL contract logistics operations typically run intense MHE activity across complex layouts, often with multiple operators across multiple shifts. Rack Armour is well suited to these environments and is widely specified across leading 3PL networks.
Cold Storage and Frozen Distribution
Cold storage environments demand materials that retain performance at sub-zero temperatures. The polymer used in Rack Armour is well suited to chilled and frozen DCs and is widely deployed across UK cold-chain operations.
Manufacturing and Industrial Storage
Manufacturing line-side storage, raw material warehouses and finished goods storage facilities all benefit from Rack Armour protection. Rapid installation suits production environments where downtime is expensive.
Pharmaceutical and Healthcare Logistics
GxP-regulated environments value the smooth polymer surface and easy-to-clean construction of Rack Armour. The visible coloured finish supports the wider GMP standards typical of pharmaceutical warehousing.
Retail Back-of-House and Trade Counters
Retail back-of-house storage, builders' merchants and trade counter operations use Rack Armour to provide visible, professional protection in environments where customers, contractors and operatives all share the warehouse space.
Self-Storage and Mezzanine Operations
Self-storage facilities and mezzanine racking installations often have high upright counts at modest individual risk per upright. Rack Armour offers a cost-effective baseline protection at scale across these environments.
Why Hall-Fast Industrial Supplies Is the Trusted Choice
Hall-Fast Industrial Supplies is a UK-based industrial supplier specialising in warehouse safety, MRO, material handling and industrial consumables. The Hall-Fast portfolio includes the complete authentic Rack Armour range alongside a wide selection of complementary safety and warehouse products from leading brands. The team is experienced in supporting UK warehouses across every sector – from FMCG distribution and e-commerce fulfilment through to manufacturing, cold storage, pharmaceutical, retail and self-storage.
UK Stock and Reliable Despatch
Hall-Fast holds Rack Armour stock in the UK and despatches everyday orders promptly. For larger projects, the team can support staged deliveries aligned to your installation schedule, ensuring stock arrives on the day it is needed without burdening your goods-in process with bulk storage.
Authenticity and Quality
Hall-Fast supplies only authentic, original Rack Armour. The market for warehouse safety products includes a number of look-alike polymer protectors, but their impact performance is rarely independently validated and their fit tolerances often vary. Specifying through Hall-Fast guarantees the engineered Rack Armour performance behind every unit.
Expert Advice and Specification Support
Hall-Fast specialists can advise on size selection, colour choice, deployment patterns, installation tooling and quantity. For larger projects the team can support a deployment plan tailored to your sites, helping you sequence the rollout to match operational windows and budget releases.
Wider Brand Portfolio
Beyond Rack Armour, Hall-Fast stocks a wide range of complementary brands covering related warehouse safety and operations needs. Sourcing through a single trusted supplier consolidates procurement, simplifies invoicing, and creates the foundation for a long-term supplier relationship.
Browse the Hall-Fast brand portfolio: https://www.hall-fast.com/brands
Read more about Hall-Fast Industrial Supplies: https://www.hall-fast.com/about
Rack Armour and UK Warehouse Compliance Frameworks
Pallet racking in UK warehouses is subject to a network of regulatory and industry frameworks. The Health and Safety Executive guidance HSG76 covers warehousing and storage, including the duty of employers to manage the risks created by interaction between people, vehicles and storage structures. The SEMA Code of Practice for the Use of Static Pallet Racking provides industry guidance on inspection and remediation, and PUWER 1998 places duties on employers in respect of work equipment.
Rack Armour does not replace any of these frameworks. Damaged uprights still need to be remediated under SEMA guidelines; the rack inspection regime still needs to be carried out daily by the PRRS and annually by a SARI; and the operating duties under HSG76 and PUWER still apply. What Rack Armour does is reduce the rate at which damage occurs in the first place, lowering the frequency of red and amber findings during inspection and reducing the operational impact of remediation events.
For organisations preparing for audit visits, regulatory inspection or insurance review, the deployment of authentic, well-specified Rack Armour at high-exposure uprights is a clear, observable demonstration of engagement with the duty to manage racking-impact risk. It complements documented training programmes, inspection regimes and incident-reporting culture as part of a credible safety case for the operation.
How to Decide if Rack Armour Is Right for Your Operation
A structured decision process helps procurement teams move quickly from interest to specification. Five questions are usually enough to confirm whether Rack Armour is the right answer and to scope the initial deployment.
Question 1: What MHE Operates on the Site?
List the MHE types in everyday use and identify the typical strike heights for each. Map those heights against the Rack Armour size range to identify the protector heights that match your strike envelope.
Question 2: Where Have Strikes Occurred?
Review the site's racking inspection records or carry out a damage walk to identify uprights with visible impact damage. These locations are the natural priority for protection – they are demonstrably exposed to the strike risk.
Question 3: What Is the Cost of Damage?
Estimate the typical cost of a remediation event, including stock decanting, specialist labour, replacement steel and operational disruption. This sets the avoided-cost dimension of the business case.
Question 4: What Is the Right Deployment Pattern?
Choose between aisle-end coverage, cross-aisle plus aisle-end, picking-face coverage, blanket coverage or hotspot-first based on the site profile and budget envelope. Hall-Fast can advise on which pattern fits best.
Question 5: What Sizes and Colours Should You Specify?
Match size to strike profile and colour to visibility need. Most sites end up with a mixed specification – Small at low-risk locations, Large or XL at aisle ends and high-traffic areas, XXL at the most exposed columns – with a consistent colour finish across the site.
Sustainability Considerations for Rack Armour
Procurement decisions increasingly include a sustainability dimension. Rack Armour offers a useful sustainability story across two dimensions: the lifecycle of the protector itself and the avoided impact of preventing rack damage.
The polymer construction has a lower embodied carbon footprint than equivalent volumes of fabricated steel guard, and the long service life of each unit – many years across many minor impacts in normal service – means the per-year embodied impact is modest. The polymer can be processed through industrial recycling streams at end of life.
More significantly, Rack Armour avoids the embodied impact associated with replacing damaged steel uprights. Fabricated steel has a meaningful carbon footprint per kilogram, and replacing a damaged upright requires manufacturing, transport and installation of new steelwork. Preventing the damage in the first place avoids that embodied impact alongside the direct operational cost. For organisations tracking Scope 3 emissions, avoided embodied impact through damage prevention is a defensible contribution to the wider sustainability narrative.
Side-by-Side Size Comparisons: When Each Pair Is the Right Decision
Specifiers often ask the same set of comparison questions when working through the size decision. Working through each comparison in turn helps clarify which size is the right answer for a particular location.
Small Versus Medium
The Small variant focuses on the lowest 300mm of the upright, while the Medium extends coverage further. Choose Small when the dominant MHE on the site is pedestrian-operated and the strike envelope is consistently below 300mm. Choose Medium when there is a mix of pedestrian and compact powered equipment, or when occasional strikes have been observed at heights just above the Small coverage zone.
Medium Versus Large
The Medium variant suits mixed light-duty operations; the Large variant suits mainstream pallet operations using compact reach trucks and small counterbalance forklifts. Choose Medium when the MHE strike envelope is transitional, with most strikes in the lower zone but occasional contact at mid-height. Choose Large when the strike envelope is consistently in the mid-zone and the operation runs mainstream powered MHE.
Large Versus XL (600mm)
The Large variant suits compact MHE; the XL extends coverage to the full 600mm zone that captures the strike profile of standard counterbalance and reach trucks. Choose Large for sites running compact, lighter equipment. Choose XL for high-throughput DCs running mainstream MHE at production cadence – this is the most commonly specified size in UK warehousing.
XL Versus XXL
The XL covers 600mm; the XXL extends beyond. Choose XL when the strike envelope is contained within the 600mm zone for the MHE in use. Choose XXL when sites operate heavy counterbalance trucks, container handlers, or drive-in racking with deep mast exposure, or when previous strikes have been observed near or above the top of an XL protector.
Mixed Three-Size Specification
Many sites end up specifying three sizes: a Small or Medium baseline across long, lower-risk runs; a Large or XL standard at all aisle ends and high-traffic locations; and an XXL upgrade at the most exposed columns. This delivers proportionate protection to the risk at each location and balances investment across the estate.
Worked Specification Examples for Common UK Warehouse Profiles
Three worked examples illustrate how the size guide translates into a specification for typical UK warehouse profiles. These examples are indicative; the Hall-Fast team can support a tailored specification for any operation.
Example 1: 30-Aisle FMCG Distribution Centre
A 30-aisle FMCG DC running 2,500kg counterbalance trucks, reach trucks and low-level order pickers needs a deployment that covers the full strike envelope. The recommended specification places XL Hi-Vis Yellow at every aisle-end upright (60 units across 30 aisles) and at every cross-aisle intersection column. Picking-face uprights along the lengths of pick aisles use the Small or Medium variant focused on low-level pick-truck contact. Drive-through entries and any column with two or more recorded strikes use the XXL variant for maximum coverage. The total deployment delivers comprehensive protection across the strike envelope of every MHE type on the site.
Example 2: Multi-Site Retail Back-of-House Estate
A national retailer running back-of-house storage across 200 stores operates predominantly with electric pallet trucks and walk-behind stackers. The strike envelope is consistently below 300mm. The recommended specification deploys the Small Safety Yellow variant as the estate standard at every front-facing upright in every store. The unit cost story makes blanket coverage commercially viable, and the consistent visual standard simplifies facilities management across the estate. Hall-Fast supports the rollout with consolidated ordering and stage-able deliveries.
Example 3: Cold Storage and Frozen Distribution Centre
A frozen DC running 2,500kg reach trucks for replenishment and low-level order pickers at picking faces needs a specification that performs at sub-zero temperatures. The XL Hi-Vis Yellow is deployed at all aisle ends for the reach truck strike envelope; the Small Hi-Vis Yellow is deployed at all picking-face uprights for low-level pick-truck contact. Hi-Vis Yellow is preferred over Safety Yellow because cold-store lighting often presents low-contrast conditions and the fluorescent shade improves visibility for operatives working in cold-weather PPE.
Procurement Scenarios: Single Order Through to Multi-Site Rollout
Rack Armour is procured across a wide range of order profiles, from a single trial unit through to multi-thousand-unit national rollouts. Hall-Fast supports every scale of procurement with the same combination of expert advice, reliable UK stock and a price promise that guarantees the most competitive UK commercial terms.
Trial Orders
Some specifiers prefer to start with a small trial deployment to validate fit, evaluate visibility under site lighting and confirm operative acceptance before committing to a wider rollout. Hall-Fast supports trial orders of any size and can advise on which sizes are most relevant to a meaningful trial.
Single-Site Deployment
A typical single-site deployment covers tens to low hundreds of units across a defined Bill of Materials. Hall-Fast supports single-site deployments with fast quotation, reliable stock availability and the option of phased delivery where installation is being carried out across multiple shift windows.
Multi-Site Rollouts
National retailers, 3PL contract logistics operators and multi-site manufacturers often roll out Rack Armour across many locations under a single contract. Hall-Fast can support rollouts with stock allocation across the programme, scheduled deliveries to each site, dedicated account management and consolidated invoicing.
Emergency or Reactive Orders
Sites occasionally need urgent stock to address a damage event or an audit finding. Hall-Fast holds UK stock and can despatch quickly to support reactive needs. Speak to the team about urgent requirements and the appropriate size recommendation for the location in question.
A Practical Specification Template
A simple specification template helps procurement teams capture the right information for every Rack Armour deployment. The template covers four sections: site information, MHE inventory, upright inventory and Bill of Materials.
Site Information
Capture the site name, address, operating hours, key safety contact and preferred installation window. This information allows Hall-Fast to align deliveries with the operational schedule and ensures the right contact receives stock arrival notifications.
MHE Inventory
List every MHE type in everyday use across the site, including manufacturer, model, capacity and travelling fork height. This information drives the size selection and helps the Hall-Fast team validate the proposed specification against the strike envelope.
Upright Inventory
Identify the count of aisle-end uprights, cross-aisle intersection columns, drive-through entries and picking-face uprights, plus any column with a recorded incident history. Mark each location category with the proposed Rack Armour size and finish. This becomes the basis for the BOM.
Bill of Materials
Translate the upright inventory into a unit count by size and finish. Add installation tools as needed (Small to Medium tool for Small and Medium deployments; Large to XL tool for Large, XL and XXL deployments). The completed BOM is the basis for a Hall-Fast quotation.
Hall-Fast Price Promise – We Will Not Be Beaten on Price
Hall-Fast Industrial Supplies offers a clear, honest commitment to every customer buying authentic Rack Armour: we will not be beaten on price. If you find a lower price for any genuine Rack Armour product anywhere else on the internet, or you have received a written quotation from another UK supplier, simply share the details with our team and we will match it. There is no small print and no awkward qualification process – the goal is to give you confidence that ordering through Hall-Fast secures the best possible commercial outcome alongside the strongest technical and aftersales support in the UK market.
The price promise applies to every Rack Armour size from Small through to XXL, in both Hi-Vis Yellow and Safety Yellow finishes, and extends to the official Rack Armour installation tools. Whether you are placing a single trial order to evaluate the product or specifying for a multi-site rollout that involves thousands of units, you can be confident that Hall-Fast will deliver the best available price together with the experience and supply reliability that larger operations demand.
To activate the price promise, request a quotation or place an order online: Contact the Hall-Fast team or visit the Rack Armour brand page to buy online.
Frequently Asked Questions About Rack Armour Sizing
Can I mix sizes across a single rack run?
Yes. Mixed specifications are common practice – most sites deploy a baseline size across long, lower-risk runs and step up to larger variants at high-traffic locations. The Hall-Fast team can advise on the optimum mix for your operation.
