Small Collision, Big Cost

How Column Protectors Prevent Warehouse Disasters

It doesn’t take much. One small bump from a forklift. One distracted driver. One unsecured column.

In a split second, a minor collision can trigger major structural damage or worse, a complete collapse.  In warehouses and industrial sites, the stakes are high, and the consequences of neglecting structural protection can be devastating.

Yet, this simple risk can be drastically reduced with one small investment: Column Protectors.

What are Column Protectors and Why are they essential?

Column protectors, also known as rack or post guards are safety barriers designed to shield structural poles, racking uprights and support columns in industrial settings.  Made from high-impact plastic, rubber, or steel, they absorb or deflect collisions from forklifts, pallet jacks, and other moving equipment.

More than just preventing dents or scrapes, they help maintain the structural integrity of your warehouse avoiding the kind of unseen damage that can compromise safety over time.

The reality is even skilled operators working in clearly marked zones can have a lapse.  In fast-paced environments, minor collisions are expected.  The smart move is putting protection in place before it becomes a bigger issue.

The Hidden Vulnerability in Your Warehouse

Most warehouses are built on strength steel columns, racking systems, concrete supports. However, while these structures are built to carry weight and withstand load, they are not designed to absorb impact.

In fast-paced warehouses, it’s not the big crashes that cause the most disruption, it’s the small, repeated bumps that go unnoticed.  A minor forklift strike to a support column might seem harmless, but over time, it weakens your structure and compromises safety.  Column protectors offer a simple, low-cost fix that absorbs impact and prevents serious damage before it starts.

Forklifts and pallet movers don’t need to be travelling fast to do damage. A low-speed impact into a support column can:

• Compromise the structural integrity of your building.
• Lead to racking system failure.
• Trigger evacuation, shut-downs or a fall-from-height event.
• Result in injuries, SafeWork investigations or prosecution.

And the cost?

Repairs to structural columns can easily exceed tens of thousands of dollars not including the indirect cost such as downtime, lost stock and damage to your reputation.

Real Incidents with Real Consequences

When it comes to safety, real stories hit harder than theory.  These are not “what if” scenarios these are actual incidents that happened in real workplaces, with real consequences for businesses and people.

Each one highlights what can go wrong when risks are overlooked or underestimated.  The lessons are clear: prevention is always cheaper than recovery.

For example:

A NSW logistics company was fined $80,000 after a racking collapse injured a worker. Investigations revealed an unreported forklift impact had weakened the structure.

In Victoria, a warehouse was temporarily closed by WorkSafe after an internal column supporting a mezzanine was struck causing visible cracking and exposing workers to the risk of collapse.

These incidents highlight the severe consequences of racking failures, emphasising the need for proactive safety measures, regular inspections and adherence to best practices in warehouse operations.​ These are often the result of not protecting columns and racking from everyday impacts.

How Column Protectors Work

Column protectors are physical barriers designed to absorb and deflect the force of an impact, shielding structural elements from forklifts, tuggers and pallet jacks.

They are typically made from:

• High-impact polyethylene
• Steel with energy-absorbing buffers
• Wraparound modular systems for easy installation

They come in bright safety colours, increasing visibility while serving as a warning to drivers. Most importantly, they do what columns cannot: take a hit and keep standing.

The Benefits of Installing Column Protectors

• Prevent structural damage
• Protect your people and plant
• Avoid expensive shutdowns and repairs
• Comply with WHS legislation and due diligence obligations
• Maintain operational efficiency without disruption

In high-traffic areas like intersections, narrow aisles and around racking systems, column protectors are not just a “nice-to-have.” They are essential.

Where to Use Them

To maximise protection, install column protectors in high-risk areas such as:

• Load/unload zones
• Aisle corners and turning points
• Base of mezzanines and support beams
• Around racking uprights
• Any structural post near forklift travel paths

The Smartest Investment You’ll Make This Year?

Warehouses are high-risk, high-traffic environments. It’s easy to overlook passive safety controls like column protectors when focused on productivity, logistics and staffing.  However, these small investments are not about damage control they’re about business continuity, legal compliance and workforce safety.

Column protectors are a smart, preventative safety measure that protects your people, equipment, and infrastructure.  They are easy to install, cost-effective and can prevent costly repairs or injury.

• Don’t wait for a close call, identify your high-traffic risk points and protect them now.
• Don’t wait for a near miss to force action. Take a proactive stance.
• Don’t Wait for an Impact – If you wait until after a collision, the damage is irreversible.

“Proactive protection is the smartest form of prevention.”

Protect Your Warehouse, Prevent Costly Disasters

If you’re not sure where your highest risks are, we can help.

Don’t leave your warehouse safety to chance. Verge Column Protectors are specially designed to safeguard your structural supports from forklift and vehicle impacts, reducing risks, costly repairs, and potential workplace incidents. Book a Warehouse Safety Audit – Click Here