oSIST prEN 18121:2025

Design and use of free standing steel rack protection for adjustable pallet racking - Upright protectors and frame barriers - Requirements and test methods

This document defines requirements and test methods for free standing and floor fixed steel upright pro-tector and free standing and floor fixed steel frame barriers for pallet racking.
Frame barriers and upright protectors, according to this document, are not connected to the rack. Frame barriers and upright protectors connected to the racking are excluded from this document.
This document does not apply to:
-   devices for traffic- or driveways
-   guide rails and guide-ins;
-   safety and buffering backstops;
-   handrails and stair rails;
-   protection from falls at height;
-   pick and deposit (P and D) stations;
-   protection requirements for dynamic storage; including mobiles;
-   protection requirements for crane racking;
-   sacrificial legs.

Auslegung und Verwendung von Anfahrschutz für verstellbare Pallettenregale - Pfosten- und Rahmenschutz - Anforderungen und Prüfverfahren

Dieses Dokument definiert Anforderungen und Prüfverfahren für freistehende und am Boden fixierte Stützen-Anfahrschutze und Rahmen-Anfahrschutze für Palettenregale.
Rahmen-Anfahrschutze und Stützen-Anfahrschutze sind nach diesem Dokument nicht mit dem Regal verbunden. Mit dem Regal verbundene Rahmen-Anfahrschutze und Stützen-Anfahrschutze sind von diesem Dokument ausgeschlossen.
Dieses Dokument ist nicht anwendbar für:
Geräte für Verkehrs- oder Fahrwege;
-   Führungsschienen und Einführungen;
-   Sicherheits- und Puffer-Auffangmechanismen;
-   Geländer und Treppengeländer;
-   Schutz gegen Sturz aus der Höhe;
-   Übergabeplätze (P und D);
-   Schutzanforderungen für dynamische Lager, einschließlich mobile Lager;
-   Schutzanforderungen für durch Regalförderzeuge bediente Regaleinrichtungen;
-   Opferstützen.

Conception et utilisation de protections en acier pour rayonnages à palettes réglables - Protecteurs des montants et des échelles - Exigences et méthodes d'essai

Le présent document définit les exigences et les méthodes d’essai pour les protecteurs de montants et les protections latérales en acier fixés au sol et autoportants pour les rayonnages à palettes.
Les protections latérales et les protecteurs des montants, selon le présent document, ne sont pas
raccordés au rayonnage. Les protections latérales et les protecteurs des montants raccordés aux
rayonnages sont exclus du présent document.
Le présent document ne s'applique pas aux :
Dispositifs pour la circulation ou les allées
-   rails de guidage et guides-entrées ;
-   butées arrière de sécurité et tampons ;
-   mains courantes et rampes d’escalier ;
-   protection contre les chutes de hauteur ;
-   postes d’enlèvement et de dépôt (P et D) ;
-   exigences de protection pour le stockage dynamique, y compris les équipements mobiles ;
-   exigences de protection des rayonnages sur pont roulant ;
-   pieds sacrificiels.

Načrtovanje in uporaba prostostoječih jeklenih zaščitnih regalov za nastavljive paletne regale - Pokončne zaščite in okvirne pregrade - Zahteve in prekusne metode

General Information

• Status: Not Published
• Public Enquiry End Date: 27-Feb-2025
• ICS: 53.080 - Storage equipment
• Technical Committee: I13 - Imaginarni 13
• Current Stage: 4020 - Public enquire (PE) (Adopted Project)
• Start Date: 19-Dec-2024
• Due Date: 08-May-2025
• Completion Date: 03-Mar-2025
• Ref Project: prEN 18121 - Design and use of free standing steel rack protection for adjustable pallet racking - Upright protectors and frame barriers - Requirements and test methods

Overview

The European Standard oSIST prEN 18121:2025, developed by CEN Technical Committee CEN/TC 344, specifies the design, requirements, and test methods for free standing steel rack protection used in adjustable pallet racking systems. This document focuses on two key components:

• Steel upright protectors
• Steel frame barriers

These components are intended to protect pallet racking uprights and frame bracing from accidental impacts caused by mechanical handling equipment (MHE), such as forklifts. Importantly, the standard applies exclusively to free standing or floor-fixed protectors and barriers that are not connected directly to the rack structure.

Key Topics

Scope and Exclusions

• The standard defines performance and testing for free standing and floor-fixed steel protective components.
• It excludes rack protection devices connected to the racking, devices for roadways or traffic lanes, guide rails, safety backstops, stair rails, fall protection, pick and deposit stations, dynamic storage, crane racking, and sacrificial legs.

Types of Protection Components

• Upright Protectors: Positioned at rack uprights, especially at corners or passageways, to shield against collisions from MHE.
• Frame Barriers: Installed at the lower part of rack frames, protecting the rear uprights and bracing elements, especially at aisle ends and passageways.

Design and Installation Requirements

• Components must comply with related standards such as EN 15629 (specification of storage equipment), EN 15512 (structural design principles), EN 15620 (tolerances and clearances), and EN 15635 (application and maintenance).
• Protection devices should:
  • Extend at least 300 mm above floor level.
  • Absorb energy of at least 400 Joules from impacts in any direction within specified height parameters.
  • Be clearly visible by using colors or stripes.
  • Be positioned so that, after impact deformation, the upright or frame structure remains uncontacted.

Mechanical Performance and Testing

• The standard provides test methods to verify energy absorption and mechanical resistance.
• Tests determine the minimum safe clearances to avoid rack damage during impacts.
• Testing protocols cover assembly, number of tests, load correction, damage assessment, and reporting.
• The acceptance criterion is that the protector or barrier prevents damage to the rack structure when subjected to defined impact loads.

Clearance Guidelines

• For upright protectors placed inside aisles, clearance requirements depend on their horizontal distance from the upright:
  • Up to 40 mm distance-no increase needed to pallet clearance.
  • Over 40 mm distance-clearance must be increased by the excess amount beyond 40 mm.
• This ensures safe maneuvering space is maintained while providing adequate protection.

Applications

The oSIST prEN 18121:2025 standard is crucial for manufacturers, warehouse operators, and safety managers focused on:

• Warehouse safety enhancement by preventing damage to pallet racks and stored goods.
• Reducing downtime and maintenance costs caused by rack damage due to forklift or MHE impacts.
• Compliance with safety regulations and improving workplace safety practices.
• Assisting designers in specifying correct rack protection that delivers reliable impact resistance and easy maintenance.
• Providing guidelines for retrofitting and installation of protection devices in existing adjustable pallet racking installations.

Proper implementation of free standing upright protectors and frame barriers protects not only physical infrastructure but also contributes to overall operational efficiency and safety culture.

Related Standards

oSIST prEN 18121:2025 references and complements several key European standards for steel static storage systems, including:

• EN 15629: Specification of storage equipment.
• EN 15512: Principles of structural design for adjustable pallet racking.
• EN 15620: Tolerances, deformations, and clearances in storage systems.
• EN 15635: Application and maintenance of storage equipment.

These related documents provide foundational requirements for the structural integrity, safety, and maintenance of pallet racking systems and are integral to implementing oSIST prEN 18121:2025 compliant rack protection solutions.

---

Keywords: European Standard oSIST prEN 18121:2025, free standing steel rack protection, pallet racking protection, upright protectors, frame barriers, adjustable pallet racks, rack safety, mechanical handling equipment protection, warehouse safety standards, steel storage systems, impact testing methods, rack damage prevention, industrial storage safety.

Standards Content (Sample)

SLOVENSKI STANDARD
01-februar-2025
Načrtovanje in uporaba prostostoječih jeklenih zaščitnih regalov za nastavljive
paletne regale - Pokončne zaščite in okvirne pregrade - Zahteve in prekusne
metode
Design and use of free standing steel rack protection for adjustable pallet racking -
Upright protectors and frame barriers - Requirements and test methods
Auslegung und Verwendung von Anfahrschutz für verstellbare Pallettenregale - Pfosten-
und Rahmenschutz - Anforderungen und Prüfverfahren
Conception et utilisation de protections en acier pour rayonnages à palettes réglables -
Protecteurs des montants et des échelles - Exigences et méthodes d'essai
Ta slovenski standard je istoveten z: prEN 18121
ICS:
53.080 Skladiščna oprema Storage equipment
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

DRAFT
EUROPEAN STANDARD
NORME EUROPÉENNE
EUROPÄISCHE NORM
December 2024
ICS 53.080
English Version
Design and use of free standing steel rack protection for
adjustable pallet racking - Upright protectors and frame
barriers - Requirements and test methods
Conception et utilisation de protections en acier pour Auslegung und Verwendung von Anfahrschutz für
rayonnages à palettes réglables - Protecteurs des verstellbare Pallettenregale - Pfosten- und
montants et des échelles - Exigences et méthodes Rahmenschutz - Anforderungen und Prüfverfahren
d'essai
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee
CEN/TC 344.
If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations
which stipulate the conditions for giving this European Standard the status of a national standard without any alteration.

This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other
language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC
Management Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and
United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2024 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 18121:2024 E
worldwide for CEN national Members.

Contents Page
European foreword . 3
Introduction . 4
1 Scope . 5
2 Normative references . 5
3 Terms and definitions . 5
4 Requirements . 9
4.1 Specification, design and inspection / maintenance. 9
4.2 Frame barrier . 9
4.3 Upright protector . 10
4.4 Mechanical performance. 13
4.5 Clearances . 16
5 Testing . 17
5.1 General. 17
5.2 Assembly of test specimens. 17
5.3 Number of tests . 17
5.4 Test criteria (definition of failure load) . 17
5.5 Test reports . 17
5.6 Corrections to test load . 18
5.7 Schedule of tests . 18
5.8 Protection testing . 19
5.9 Testing to determine the level of damage . 23
5.10 Analysis of results . 23
6 Documentation . 24
6.1 Installation details . 24
6.2 User manual . 24
6.3 Inspection and maintenance. 24
Annex A (informative) Selection criteria and inspection . 25
A.1 Use of rack protection . 25
A.2 Inspection criteria of the rack protection . 26
Annex B (informative) Loadings . 27
Annex C (informative) Retro-fitting of protectors . 29
Bibliography . 30

European foreword
This document (prEN 18121:2024) has been prepared by Technical Committee CEN/TC 344 “Steel static
storage systems”, the secretariat of which is held by UNI.
This document is currently submitted to the CEN enquiry.
Introduction
The purpose of this document is to provide information on the requirements, design, use and test proce-
dures of steel upright protectors and steel frame barriers, not connected to the rack (free standing), for
pallet racking.
Such protection reduces the risk of contact to uprights and upright frame bracing members depending
on the level of impact, but are usually incapable of stopping a travelling truck.
Adequate protection depends on a number of parameters, to be defined as part of a risk assessment.
Appropriate operator training and safety measures avoid contact caused by fork-lift trucks or other mov-
ing equipment against rack-uprights.
As requirements and test procedures given in this document base on free-standing steel upright protec-
tors and free-standing steel frame barriers, these requirements and test procedures may be taken as
guideline for non-steel products, whereas a declaration of those products against this document is explic-
itly not intended.
1 Scope
This document defines requirements and test methods for free standing and floor fixed steel upright pro-
tector and free standing and floor fixed steel frame barriers for pallet racking.
Frame barriers and upright protectors, according to this document, are not connected to the rack. Frame
barriers and upright protectors connected to the racking are excluded from this document.
This document does not apply to:
— devices for traffic- or driveways
— guide rails and guide-ins;
— safety and buffering backstops;
— handrails and stair rails;
— protection from falls at height;
— pick and deposit (P and D) stations;
— protection requirements for dynamic storage; including mobiles;
— protection requirements for crane racking;
— sacrificial legs.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content consti-
tutes requirements of this document. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
EN 15629, Steel static storage systems - Specification of storage equipment
EN 15512, Steel static storage systems - Adjustable pallet racking systems - Principles for structural design
EN 15620, Steel static storage systems - Tolerances, deformations and clearances
EN 15635, Steel static storage systems - Application and maintenance of storage equipment
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
• ISO Online browsing platform: available at https://www.iso.org/obp
• IEC Electropedia: available at https://www.electropedia.org/
3.1
frame barrier
free standing and floor fixed steel component(s) to protect the lower part of upright frames at the ends
of runs and at passageways against accidental impact from mechanical handling equipment (MHE)
Note 1 to entry: See Figure 1.
Note 2 to entry: Figure 1a shows a possible combination of a frame barrier with an upright protector. According to
the design of the frame barrier it could also be installed by itself (see Figure 1b).

Key
m frame barrier
g upright protector
a) Examples of a frame barrier in combination with an upright protector

Key
f frame barrier
b) Example of a frame barrier
Figure 1 — Examples of frame barriers
3.2
upright protector
free standing and floor fixed steel component to protect the lower part of uprights against accidental
impact from mechanical handling equipment (MHE)
Note 1 to entry: See Figure 2.

Key
h upright protector (for corner protection)
a) Example of an upright protector (for corner protection)
Key
i upright protector (in-aisle protection)
b) Example of an upright protector (for in-aisle protection)
Figure 2 — Examples of upright protectors
4 Requirements
4.1 Specification, design and inspection / maintenance
Frame barriers and upright protectors shall be specified according to EN 15629 and designed in accord-
ance with EN 15512 and EN 15620.
NOTE 1 Annex A provides further information about the selection criteria of rack protection.
Installation instructions shall include instructions for person(s) responsible for storage equipment safety
in accordance with EN 15635 and training information of the staff / operator.
Inspection and maintenance shall be in accordance with EN 15635.
NOTE 2 Rack protection included in the rack design is part of the design of the rack.
4.2 Frame barrier
Frame barriers can optionally be located close to the rear uprights of the end frame and frame bracing at
each side of a passage way (see Figure 3) to provide
• a visual warning,
• a physical barrier for the front and side of the corner upright for mechanical handling equipment
entering an aisle
and
• a physical barrier to the goods, pallets and/or loads for the protection of the rear upright and bracing.
Frame barriers are available in a variety of forms and if used:
• they shall be positioned in such a way that, after its deformation by absorbing an impact, the upright
will not be contacted,
• they shall be a minimum of 300 mm height from floor level,
• the protector rail shall extend between 75 mm above the floor to the specific height of the frame
barrier,
• they shall be made conspicuous by colours and/or stripes,
• they shall be designed for an energy absorption of at least 400 J in any direction at any height be-
tween 75 mm from floor level and 50 mm below the height of the frame barrier.
NOTE 1 See also 4.5.2 for recommendations of positioning the frame protection.
NOTE 2 Lager sizes of frame protections are designed according to individual tests.
NOTE 3 The protector rail could extend below the test level of 75 mm to reduce the risk of MHE forks going under
the rail.
Frame barriers can be designed as stand-alone device (see Figure 1, m) or combined with an upright pro-
tector (for corner protection) (see Figure 1, m combined with g).
Protection by frame barriers is optional and based on user's risk assessment, but recommended for the
rear uprights and frame bracing where goods are stored at the ends outside of a run.
4.3 Upright protector
4.3.1 Upright protector (for corner protection)
Upright protectors (for corner protection) (see Figure 2a) shall be installed
• at the uprights (at the end of the rack)
and
• at the uprights at each side of a passage way (see Figure 3).
Upright protectors (for corner protection) are available in a variety of forms and they shall:
• be positioned in such a way that, after its deformation by absorbing an impact, the upright will not
be contacted,
• be a minimum of 300 mm height from floor level,
• be made conspicuous by colours and/or stripes,
• be designed for an energy absorption of at least 400 J in any direction at any height between 75 mm
from floor level and 50 mm below the height of the frame barrier.
NOTE 1 Larger sizes of frame protections are designed according to individual tests.
Upright protectors (for corner protection) can be designed as stand-alone devices (see Figure 2a) or com-
bined with a frame barrier (see Figure 1a).

Figure 3 — Plan of rack protection location
Upright protectors (for corner protection) are available in a variety of forms and shall be designed ac-
cording to 4.4.2.
4.3.2 Upright protector (for in-aisle protection)
Upright protectors (for in-aisle protection) (see Figure 2b) can optionally be installed in bays for the pro-
tection of the frame when placing pallets or products (see Figure 3).
If upright protectors for in-aisle protection are used:
• upright protection (for in-aisle protection) with a maximum horizontal distance of up to 40 mm from
the upright are allowed within the clearance in a bay, with no increase in the clearance requirements
as specified in EN15620 (see Figure 4a),
• upright protection (for in-aisle protection) with a maximum horizontal distance over 40 mm from
the upright shall increase the clearance requirements by the horizontal dimension, minus 40 mm
(see Figure 4b).
a) Clearance of an upright protector (for in-aisle protection) when the edge of the upright pro-
tector is less than or equal to 40mm from the side of the upright
b) Clearance of upright protector (for in-aisle protection) when the edge of the upright protector
is greater than 40mm from the side of the upright
Key
DIM ‘A’ Dimension A: Standard EN15620 Code clearance between pallet or load and upright
DIM ‘B’ Dimension B: Additional clearance when the edge of the column protector is greater than 40mm from
the side of the upright
DIM ‘C’ Dimension C: Increased clearance (dimension A + dimension B)
Figure 4 — Clearance of upright protectors
NOTE 1 Protection of internal uprights within an aisle is optional and based on user's risk assessment.
NOTE 2 Upright protectors, for corner protection and in-aisle protection can be achieved by an alike device; the
specific installation requirements are important.
If the function of an upright protector for in-aisle protection is combined with the function of an upright
protector for corner protection, the requirements for upright protector for corner protection (see 4.3.1)
shall be considered.
4.4 Mechanical performance
4.4.1 General
...