What are steel UPN end-of-aisle protectors for pallet racking?
Steel UPN end-of-aisle protectors are designed to shield pallet racking ends from accidental impacts caused by material handling equipment. In warehouses where forklifts and pallet trucks operate, these areas are particularly vulnerable to collisions during loading, unloading and turning manoeuvres. Even a minor impact can deform the end frame and compromise its load-bearing capacity. In more severe cases, the damage may contribute to structural failure, potentially causing stored goods to fall from the upper levels.
Steel UPN end-of-aisle protectors are designed to absorb impacts and prevent them from reaching the racking structure. They consist of a standard U-shaped steel channel (UPN) anchored to the floor in front of the end-frame uprights and at other locations particularly exposed to collision risks, such as aisle intersections. The protector is installed at a suitable distance from the racking frame so that, in the event of an impact, it takes the force of the collision rather than the racking upright.
Where to install steel UPN end-of-aisle protectors
The need to protect racking ends depends on the warehouse’s operating conditions, particularly the presence of forklifts, pallet trucks and other material handling equipment operating near the structures. The risk is therefore primarily determined by traffic flows and the space available for manoeuvring, rather than by the industry in which the warehouse operates. Third-party logistics, food distribution, manufacturing and large-scale retail can all present similar levels of exposure to impact risks.
Particular attention should be paid to racking row ends exposed to vehicle traffic, aisle intersections and other areas where manoeuvres are frequent or space is limited. The choice and positioning of protectors should reflect the racking layout and the actual routes used by material handling equipment.
Technical specifications of steel UPN end-of-aisle protectors
Steel UPN end-of-aisle protectors are anchored directly to the floor, without requiring any modifications to the existing racking structure. The length and thickness of the steel channel are selected according to the racking layout and the conditions in the area to be protected, ensuring adequate coverage of uprights exposed to impact risks.
- Material: steel, with a standard U-shaped channel profile (UPN)
- Fixing: floor-mounted using anchoring systems suitable for the substrate
- Compatibility: single- and double-entry racking, adapted to the specific geometry of the frame
- Sizing: determined according to the racking layout and installation conditions
Benefits of steel UPN end-of-aisle protectors
Installing a dedicated barrier at the end of a racking row helps protect the frame from direct impacts by material handling equipment, reducing the risk of damage in areas with heavy traffic and frequent manoeuvring.
- Absorbs frontal impacts before they reach the racking frame, helping reduce the risk of upright deformation.
- Suitable for areas most exposed to impacts, such as forklift aisles and aisle intersections.
- Can help reduce long-term costs associated with replacing damaged components and the resulting operational downtime.
- Can be installed on existing racking, with a configuration tailored to the specific frame, without the need to replace the existing structure.
Regulatory references for pallet racking impact protection
Racking impact protectors are among the components assessed during inspections carried out in accordance with UNI EN 15635, together with uprights, end frames and other structural elements. Any damage or defects identified must be evaluated and addressed in line with the standard’s guidance and risk assessment criteria.
The management of equipment and workplace safety is also governed by the requirements set out in Italian Legislative Decree 81/2008.
Custom-designed end-of-aisle racking protectors
Selecting the right end-of-aisle protector depends on several factors, including the racking frame configuration (single- or double-entry), the volume of forklift and pallet truck traffic, and the layout of aisles and intersections. We assess the racking layout and material handling operations to determine the most suitable type of protection, dimensions and installation points for structures most exposed to impact risks.
FAQ
There is no general legal requirement to install a specific type of impact protector on every pallet racking system. However, UNI EN 15635 provides for the use of protective devices in areas exposed to impact from material handling equipment, with the aim of reducing the risk of structural deformation. Workplace and equipment safety is also governed by Italian Legislative Decree 81/2008, which requires risks to be assessed and appropriate preventive and protective measures to be adopted.
Yes. The UPN protector is designed for use with different types of racking frames, including both single- and double-entry configurations. It is anchored directly to the floor and does not require modifications to the existing racking structure.
The protector is anchored directly to the floor using anchor bolts, in front of the racking end frame or at the point identified as most exposed to impact, while maintaining a safe clearance from the upright. Installation does not require modifications to the racking structure and can also be carried out on existing racking in operational warehouses.