In a dynamic warehouse environment, where forklifts maneuver with heavy loads, collisions are almost inevitable. The key to minimizing losses is not just careful driving, but above all, the physical protection of the warehouse infrastructure.
Why is the lower part of the rack upright most vulnerable to damage?
Statistics show that most rack damage occurs within the first 100 cm of the upright’s height. This is the maneuvering zone for the forks and wheels of the forklift. Even a slight impact from a truck weighing several tons can compromise the load-bearing structure of the upright, weakening the stability of the entire rack section.
Types of passive safety measures in the warehouse
Various solutions are available on the market designed to absorb impact energy.
Steel vs. plastic bollards – pros and cons
- Steel bollards: A traditional, extremely durable solution anchored to the floor. Their advantage is a low price and high resistance to abrasion. The disadvantage is that during a very strong impact, the energy can be transferred to the floor, causing damage to the concrete around the anchors.
- Plastic (flexible) guards: A modern solution that “works” during an impact, absorbing energy and returning to its original shape. They protect the rack, the floor, and the forklift itself.
Corner guards vs. upright protectors – where to install them?
Corner guards (L-shaped) are installed on the end uprights of rows, where the risk of impact during turning is highest. Upright protectors (U-shaped) are used on intermediate uprights, especially in narrow working aisles.
Frame protectors (end-of-aisle barriers) – protecting working aisles
To protect the entire depth of the frame (e.g., at cross-aisles), end-of-aisle barriers are used, connecting two corner guards with a beam, often made of wood or steel. This creates a physical barrier preventing the truck from driving into the frame structure. This is crucial for proper forklift traffic organization.
Cost of upright replacement vs. cost of guard installation – cost-benefit analysis
The cost of a professional guard is a fraction of the price of replacing a damaged upright. It should be remembered that replacing an upright involves not only the purchase of the component and the service fee but, above all, the need to unload goods and take part of the warehouse out of use for several hours.
How to choose the right guards for the type of forklifts?
The selection of rack accessories depends on the weight of the trucks and the speed at which they move. In manual picking zones, lighter guards are sufficient, while in main transport routes, massive anchored bollards are necessary.