Rack Armour® XXL Upright Racking Protectors - Hi Vis Yellow

The Largest Size in the Rack Armour® Range — Built for the Heaviest Racking

The Rack Armour® XXL Upright Racking Protector is the top of the standard Rack Armour® range, sized to fit front-facing uprights up to 135mm wide (Euro E). It's specified for the heaviest industrial pallet racking — pallet shuttle systems, very high-bay installations, narrow-aisle and very-narrow-aisle (VNA) racking, and any engineered racking carrying loads at the upper end of typical pallet weights. Where a damaged upright means rack inspection contractors, bay isolation, and stock relocation, the XXL upright protector pays back its cost on the first prevented impact.

Standing 600mm tall in high-visibility yellow, it clips onto the upright by hand without anchors or drilling. The patented HDPE outer shell deflects forklift and MHE 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 for the largest standard upright profiles.

Our Price 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.

Why It Outperforms Heavy Steel Column Guards on Specialist Racking

On engineered racking, specifying steel column guards can introduce as many problems as it solves. Bigger guards transfer bigger forces — into the upright, the floor, or the anchor zone immediately around it. On VNA, shuttle, and high-bay systems where racking tolerances are tight and floor flatness matters, that's a meaningful risk. Rack Armour® takes the opposite approach:

• Absorbs and dissipates impact energy rather than passing it through the upright or floor
• Zero floor fixings — no anchors, no drilling, no compromise to floor flatness in VNA installations
• No corrosion, no deformation under repeat impact
• Lifts off in seconds for the racking inspections required under FEM and HSE guidance
• Independently tested to FEM 10.2.16

Specified for the Most Demanding Warehouse Environments

The XXL size is most often found in the warehouses that punish equipment hardest: high-throughput distribution centres, third-party logistics sites running mixed MHE, automotive and tyre storage, beverage and FMCG warehouses with heavy pallet weights, and specialist freezer storage. Rack Armour® XXL is rated to -40°C, resistant to moisture, corrosion, and most industrial solvents, and engineered for repeat impact across 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 the largest standard upright profiles up to 135mm wide (Euro E)
• 600mm height — covers the strike zone where forklift damage occurs
• Hi-vis yellow finish for clear MHE driver awareness in busy or constrained aisles
• 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
• 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. Typical installations include pallet shuttle and semi-automated racking, very high-bay storage in larger distribution centres, narrow-aisle and very-narrow-aisle (VNA) installations, deep-lane and drive-in heavy-load systems, automotive parts and tyre storage, and beverage and FMCG warehouses carrying heavier-than-average pallet weights. They're also common on bespoke engineered racking specified for unusually heavy loads or unusually tall bay configurations.

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.

When the Cost of Not Protecting Is Highest, Protection Pays Back Fastest

Damage to an Euro E upright tends to come with the highest follow-on costs in the building — not just the repair, but the bay isolation, stock relocation, contractor visit, and operational disruption that usually go with it. Rack Armour® XXL Upright Protectors clip on in seconds and start absorbing impacts immediately. 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 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 and is suited to the heaviest industrial pallet racking profiles.

How do I choose between XL (Euro D) and XXL (Euro E)? Measure the front-facing width of your racking upright in millimetres. Above 110mm and up to 120mm = Euro D / XL. Above 120mm and up to 135mm = Euro E / XXL. If you're unsure, send through your racking specification or a photo of the upright with a tape measure and we'll confirm the right size.

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.

Is Rack Armour® suitable for VNA and shuttle racking? Yes. The XXL size is the typical fit for the larger uprights used on VNA, very-narrow-aisle, and pallet shuttle racking. The clip-on design is particularly useful in these installations because it doesn't require floor fixings, which can interfere with the floor flatness specifications VNA systems depend on.

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, and no floor damage is introduced — which is especially valuable on engineered or precision floor 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 freezer environments? Yes. Rack Armour® is rated to operate at temperatures down to -40°C without loss of performance, suiting it to chilled, frozen, and ambient 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 XXL upright protector has a 15+ year design life and can absorb 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.

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.