Small Collision, Big Cost: How Column Protectors Prevent Warehouse Disasters

In warehouses and storage facilities, often the small incidents carry the biggest price tags.  A minor collision between a forklift and a structural column may not look catastrophic at first glance, however, the reality is very different.  The cost of repairing structural damage, downtime, and the potential risks to worker safety can quickly escalate.

Column protectors may seem like a simple piece of safety equipment, but their role in preventing workplace disasters cannot be overstated.

Why Structural Columns are at Risk

Warehouses and storage facilities are dynamic environments.  With forklifts, pallet jacks, order pickers, and other vehicles constantly moving, the risk of accidental impacts is ever-present.  Columns positioned in high-traffic zones are vulnerable to collisions, particularly where visibility is reduced, corners are tight, or workflow pressures increase the likelihood of human error.

Even a “small” impact can compromise the structural integrity of a building.  Damaged columns may not fail immediately, but they can weaken over time, creating long-term hazards that put workers, equipment and the facility itself at risk.

The Real Cost of “Minor” Collisions

When a warehouse column is impacted, it often isn’t as simple as repairing or replacing the damaged steel or concrete. In many cases, businesses are legally required to bring in a structural engineer to assess the damage and certify the column as safe. This process not only adds significant expense, but can also cause long delays while inspections, reports, and re-certifications are carried out.

Engineering assessments can run into thousands of dollars, and if the damage is extensive, the costs quickly escalate. On top of the fees, businesses may need to shut down or restrict operations in the affected area until clearance is given, compounding the financial impact through lost productivity.

What might appear as a “small dent” can end up triggering a chain of compliance obligations and unexpected costs that far outweigh the investment in preventative protection like column guards.

Repair costs

Fixing structural damage is costly.  A small impact today can mean extensive repairs tomorrow.

Downtime

Damaged columns can force part of the warehouse to shut down for safety reasons, disrupting operations and productivity.

Injury risks

 A weakened column poses a serious safety hazard to anyone working in its vicinity.  In worst-case scenarios, structural failure could lead to fatalities.

Legal and financial liability

Under the Work Health and Safety Act 2011, business owners and leaders have a duty to provide a safe workplace “so far as is reasonably practicable.” Ignoring impact protection exposes both the business and its leaders to significant penalties.

What looks like “just a dent” could end up costing thousands or importantly a fatality or serious injury.

Column Protectors: A Simple, Effective Solution

Column protectors are designed to absorb and deflect the force of impacts, shielding structural supports from damage.  Made from durable materials like polyethylene or reinforced steel, they create a buffer between moving vehicles and critical infrastructure.

The benefits of column protectors include:

• Impact absorption – They minimise damage from forklifts, pallet jacks and other equipment.
• Worker protection – Reducing the risk of structural failure directly safeguards employees.
• Cost savings – Preventing damage reduces maintenance, repairs and insurance costs.
• Operational continuity – By protecting columns, businesses avoid unnecessary downtime and disruption.

In short: column protectors are not an optional extra.  They are an investment in safety, compliance and long-term operational efficiency.

High-Risk Areas Where Column Protectors Are Essential

Not all parts of a warehouse carry the same risk.  When reviewing your facility, pay special attention to:

• High-traffic forklift routes – Columns positioned along main transport paths are at greater risk.
• Blind corners and intersections – Limited visibility increases collision likelihood.
• Loading dock areas – Fast-paced activity and tight spaces make impacts more frequent.
• Narrow aisles – Reduced clearance leaves little margin for driver error.
• Racking zones – Protecting columns near heavy pallet racking prevents secondary collapses.

If these areas in your warehouse are not currently protected, they should be.

Column Protection and Compliance

Column protectors play a vital role in helping businesses meet compliance obligations under WHS legislation.  SafeWork NSW and other regulatory bodies emphasise the importance of eliminating risks where possible and minimising them through effective controls when elimination is not practical.

Impact protection falls squarely into this category.  By installing column protectors, PCBUs (Persons Conducting a Business or Undertaking) can demonstrate that they have taken “reasonably practicable” steps to manage foreseeable risks, a key test in WHS compliance.

Practical Steps for Implementation

If your warehouse has not yet addressed column protection, here’s where to start:

1. Conduct a safety inspection – Identify high-risk areas where collisions are most likely.
2. Select the right protectors – Choose protectors suited to your column size, material, and impact risk level.
3. Install strategically – Prioritise high-traffic, high-impact zones first.
4. Monitor and review -Regularly inspect protectors for damage and replace when needed.
5. Train workers – Reinforce safe driving practices and ensure operators understand why protectors are in place.

Beyond Protectors: A Layered Approach to Safety

Column protectors are a critical control, but they work best when combined with broader traffic management strategies.  These may include:

• Clearly marked pedestrian walkways
• Speed limits for forklifts
• Convex mirrors at blind spots
• High-visibility signage
• Regular driver refresher training
• A documented traffic management plan

Together, these measures create a safer warehouse environment where risks are controlled at multiple levels.

Small Investment, Big Protection

Too often, businesses only take column protection seriously after an incident has already occurred.  But by then, the damage, financial, operational or human may be too late to undo.

Column protectors are a relatively small investment that can prevent catastrophic outcomes.  For warehouses and storage facilities, where high-risk interactions between people, vehicles, and infrastructure are part of everyday operations, they are not optional they are essential.

A Safe Warehouse is a Productive Warehouse.

We offer complete safety solutions wherever barriers are required for your industry or workplace. View our product range, or contact the team for more information.