Rack Armour® XXL Upright Racking Protectors - Safety Yellow

The Largest Size in the Range — In the Industrial Standard Finish

The Rack Armour® XXL Upright Protector is the top of the standard Rack Armour® range, sized to fit front-facing uprights up to 135mm wide (Euro E). The Safety Yellow variant is most often specified in two contexts: completing a coordinated Safety Yellow rollout across a site that runs mixed upright sizes, and heavy-duty industrial applications where the racking sits in well-lit ambient or covered environments rather than dim cold stores or narrow-aisle interiors.

It clips onto the upright by hand in seconds — no anchors, no drilling, no contractors — and delivers the same independently verified 80% reduction in racking damage as the rest of the range, in the standard industrial Safety Yellow that integrates with existing bollards, kerb protection, and floor markings.

Our Price Promise: We won't be beaten on price for any authentic Rack Armour® product. Send us a lower online price or written quote and we'll match it. Project and bulk pricing is available — talk to us about combined orders across multiple sizes.

Where Safety Yellow XXL Is Specified

Two main scenarios drive Safety Yellow at this size:

1. Completing a Safety Yellow rollout across mixed upright sizes. Sites running varied racking profiles often have a few bays with larger Euro E uprights — typically older heavy-duty racking, bespoke engineered runs, or specialist high-load sections sitting alongside the rest of the building. When the site standard is Safety Yellow on the Medium and Large sizes, the XXL needs to match. This is the most common reason customers buy the XXL in Safety Yellow rather than Hi-Vis.

2. Heavy industrial applications in well-lit ambient environments. Steel stockholders, builders' merchants and timber merchants, automotive parts stores, agricultural feed and grain stores, paper and packaging warehouses, and covered yard storage. These run heavier-duty racking in well-lit conditions where the standard industrial Safety Yellow gives clear visibility without the fluorescent finish, and where Safety Yellow's pigment stability outperforms Hi-Vis in any partially-exposed or UV-affected zones.

When the Hi-Vis Yellow Variant Is the Better Choice

Worth being clear: at the XXL size, the two finishes are not interchangeable across all applications. Choose the Hi-Vis Yellow variant instead of Safety Yellow for:

• Very-narrow-aisle (VNA) and narrow-aisle racking — tight aisle widths and reduced ambient light favour the brighter fluorescent finish
• Pallet shuttle and deep-lane systems — drivers need stronger visual cues for the upright at the entry to the lane
• Cold and frozen storage with low ambient lighting — Hi-Vis stands out where Safety Yellow can read as muted under cold-store fluorescents
• Drive-in racking interiors — forklifts operate inside the rack run; brighter is better

Many specifications combine both: Safety Yellow as the building standard, Hi-Vis as a zone exception for the applications above. We can quote both finishes within a single project order.

Same Proven Performance, Built for Long Service

The patented HDPE outer shell deflects forklift and MHE impacts while the high-density foam core absorbs the energy before it reaches the racking leg. Unlike steel column guards, which transfer impact force into the upright or rip out floor anchors:

• No floor fixings — clips on by hand without anchors, drilling, or floor damage
• Won't deform, rust, or split under repeat impact
• Lifts off in seconds for the rack inspections required under FEM and HSE guidance
• Independently tested to FEM 10.2.16

Rack Armour® is rated to operate at temperatures down to -40°C, resistant to moisture, corrosion, and most industrial solvents, and designed for repeat impact resistance over a 15+ year service life. The Safety Yellow finish uses a standard industrial pigment that holds its colour over the full service life — particularly useful in any partially UV-exposed locations like covered yards or warehouses with skylights, where fluorescent finishes can fade more visibly.

Key Features

• Patented HDPE outer shell with high-density energy-absorbing foam core
• Independently verified 80% reduction in racking damage
• Sized for the largest standard upright profiles up to 135mm wide (Euro E)
• 600mm height — covers the strike zone where forklift damage occurs
• Standard industrial Safety Yellow finish — coordinates with existing yellow infrastructure
• Tool-free clip-on installation — no anchors, drilling, or floor compromise
• Tight grip stays on after impact
• Operating range down to -40°C
• Tested to FEM 10.2.16
• 15+ year design life
• UV-stable pigment for partially exposed and covered yard installations
• Project and bulk pricing available
• Custom branded labels available — add request to order notes at checkout

Specifications

Where the XXL (Euro E) Size Fits

Euro E 135mm uprights sit at the top end of the standard pallet racking profile range. Common XXL Safety Yellow installations include heavy industrial pallet racking in steel stockholders, builders' merchants, automotive parts and engineering stores, agricultural feed and grain warehouses, paper and packaging storage, covered yard pallet racking, and bespoke engineered racking on well-lit ambient sites. They're also used to complete coordinated Safety Yellow rollouts on mixed-size racking estates where the bulk of the order sits in Medium or Large but a handful of larger uprights need matching.

If you're not sure whether you need Euro D or Euro E, measure the front-facing width of the upright in millimetres: above 120mm and up to 135mm sits in the XXL bracket. If your uprights are wider than 135mm, contact us — we can advise on the right protection approach for non-standard installations.

Complete Your Rollout, or Specify From Scratch

Whether you're filling out a coordinated Safety Yellow rollout or specifying heavy-duty rack protection for a steel stockholder, builders' merchant, or covered yard installation, the XXL Safety Yellow gives you the largest size in the range in the industrial standard finish. Add to your order today, or get in touch for combined quotes across multiple sizes and finishes.

Should I order Safety Yellow or Hi-Vis Yellow XXL? Choose Safety Yellow if your application is heavy industrial racking in well-lit ambient or covered conditions (steel stockholders, builders' merchants, agricultural stores, automotive parts), or if you're completing a Safety Yellow rollout that already covers your other upright sizes. Choose Hi-Vis Yellow for VNA and shuttle racking, drive-in interiors, deep-lane systems, and cold or frozen storage with low ambient lighting. Many specifications combine both — Safety Yellow as the building standard with Hi-Vis as a zone-specific exception.

What size pallet racking does the XXL Rack Armour® protector fit? The XXL (Euro E) size fits front-facing uprights from above 120mm and up to 135mm wide. This is the largest size in the standard Rack Armour® range.

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

How do I choose between XL (Euro D) and XXL (Euro E)? Measure the front-facing width of your racking upright. Above 110mm and up to 120mm = Euro D / XL. Above 120mm and up to 135mm = Euro E / XXL.

Will the Safety Yellow finish fade if the racking is in a covered yard or near skylights? The standard industrial pigment used in Safety Yellow holds its colour well over a 15+ year service life and is more UV-stable than fluorescent finishes. It's a common choice for covered yard storage, agricultural buildings with translucent roof panels, and warehouses with significant rooflight coverage.

Do you handle mixed-size project orders? Yes. Most heavy-duty rollouts include a mix of Medium, Large, XL, and XXL units to fit varied upright profiles across the same site. Contact us with your specification and site layout and we can quote combined volume across all sizes — and across both finishes if needed.

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, even at the XXL size. This makes the product especially attractive on engineered floor installations where anchor work would compromise the floor specification.

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.

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 XXL upright protector has a 15+ year design life and absorbs multiple impacts before needing replacement, depending on the force of each strike.

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. Project-level pricing is also available beyond the standard price match for multi-size and high-volume orders.