Guide Rails Adelaide
Overview of guide rail systems
The guide rails Adelaide businesses rely on are more than just barriers – they’re peace of mind. In high-traffic warehouses, even a minor forklift misjudgement can cause major damage. Rackman Australia supplies and installs heavy-duty guide rail systems that protect your racking, define safe traffic zones, and keep operations running safely.
Whether you’re using drive-in racking or navigating tight aisles, guide rails add control, structure and safety where it matters most.
Guide rails are low-profile steel barriers anchored to the warehouse floor. Their role is to keep forklifts on course, pallets aligned, and infrastructure protected. Like a kerb, they create a physical boundary that guides and safeguards without restricting access.
Our guide rails are commonly used to:
- ***Protect pallet racking uprights in very narrow aisle (VNA) systems
- ***Guide forklifts through drive-in and drive-through racking lanes
- ***Shield infrastructure like conveyor legs, door tracks, or columns
- ***Define safe forklift and pedestrian traffic zones
- ***Support compliance with WHS standards and risk mitigation protocols
Paired with pallet racking, drive-in racking, or a full warehouse racking system, guide rails deliver critical protection in high-congestion spaces.
Guide rails designed for your Adelaide warehouse
Every site has different needs, which is why our guide rails are custom-designed to match your exact layout. We’ll assess:
- ***Aisle widths and forklift types
- ***Pallet dimensions and turning radii
- ***Existing racking configurations (such as any form of pallet racking)
- ***Traffic flow patterns, intersections, and pedestrian routes
From there, we design and fabricate a rail system using high-strength angles or box-section profiles. All components are powder-coated safety yellow or striped for visibility, and installation is calibrated for alignment, spacing, and impact resistance.
Industries we’ve installed guide rails for
Guide rails have a place in almost every kind of warehouse where safety is a priority.
3PL & logistics
- to keep high-volume forklift traffic aligned in pick-pack and shipping zones
Manufacturing
to protect fixed plant, machinery and racking in production areas
Cold storage & food warehousing
- where condensation and floor slipperiness make control vital
Retail distribution
- to safeguard high-value racking and stock in fast-paced loading areas
Automotive & tyre warehousing
often used alongside Tyrespan systems
Building materials & steel yards
to manage heavy pallets and irregular loads near cantilever racking
Key features of Rackman’s guide rail systems
Our guide rails typically measure 75mm to 150mm high and are designed to align with the forklift’s wheel or outrigger height, providing a consistent physical reference. The height is carefully chosen to remain effective without becoming a trip hazard or interfering with pallet movement. At the start of each rail run – especially in drive-in applications – we can taper or flare the ends to create a smooth entry point, reducing jarring impacts and assisting with pallet guidance.
Heavy-duty steel construction
Fabricated from 10mm+ steel in L-angle or formed profiles, our guide rails are built to endure constant forklift contact. Modular 3m sections allow seamless installation across long aisles, with reinforced anchoring every 600–1000mm for stability.
Precision fabrication and fit
We fabricate rails in modular lengths (usually 3m) that can be bolted to the floor or linked together for continuity. For aisle ends or high-traffic intersections, we can extend rails to shield racking end frames and incorporate end guards or bullnose barriers. If your floor is uneven or sloped, our installers adjust the rail height using industrial shims, ensuring level contact throughout. Each system is tailored to your warehouse. In drive-in racking bays, we space rails perfectly to match pallet dimensions, reducing friction and eliminating drift. In VNA racking, rails align with turret truck rollers to ensure consistent centring.
Smooth edges and clean visibility
All rails are coated in high-visibility finishes (yellow, black/yellow hazard striping) and designed with flared entries, bevelled tops, and smooth corners to prevent tyre damage or snagging. Reflective tape can also be added for low-light environments.
Integrated traffic management
Guide rails are more than physical barriers – they’re part of your warehouse safety ecosystem. We can integrate them with floor striping, upright protection, bollards, or signage to define clear, functional flow zones.
Benefits of installing guide rails
Prevent costly damage to uprights and frames. One misjudged turn can compromise structural integrity, trigger a rack collapse, or halt operations. Guide rails absorb the blow and redirect forklifts before impact. Like insurance for your racking.
In tight aisles, every centimetre counts. Guide rails remove guesswork, helping forklift operators stay aligned and move faster. In drive-in systems, they simplify pallet centring. In narrow lanes, they reduce anxiety and allow for smoother, safer motion.
Guide rails enforce boundaries between vehicles, pedestrians, and storage. They reduce the risk of tip-overs, near-misses, and off-course collisions. Bright finishes and physical cues increase spatial awareness, a crucial layer of defence in busy operations.
They don’t just protect racking. Guide rails can shield walls, dock edges, columns, conveyors, and expensive equipment. We install them wherever forklift drift poses a threat, including mixed-use zones with automated systems and AGVs.
Our systems are designed to last – with reinforced welds, modular sections for easy replacement, and corrosion-resistant finishes. In the rare event of extreme impact damage, we can quickly repair or swap out individual rail segments.
Our guide rail service in Adelaide
Before we get to work, we review your warehouse plans, vehicle types, and aisle dimensions to ensure the system adds value without disrupting movement or access. If you already have pallet cages, cable racking, or other specialised racking in place, we’ll ensure the guide rails work in harmony with your existing equipment.
We map out high-risk zones, turning circles, and traffic routes to create a rail plan tailored to your operations.
We use chalk lines and laser levels to anchor rails precisely. Work is done safely and efficiently, often aisle-by-aisle to reduce disruption.
Your rails won’t exist in isolation. We align them with drive-in racking, vertical racking, signage, floor markings, and more.
Need to reconfigure? Upgrade? Repair a damaged section? We’re here long-term, with records on file to match rail types and spacing.
Based on your needs, we cut each rail section to precise length and spec. We have an in-depth design and consultation process to ensure we can deliver the best guide rails for your specific operation.
What to consider before installing guide rails
Consider the size, weight, and manoeuvrability of your equipment. Forklifts with outriggers, electric pallet jacks, and AGVs all require different clearances and handling zones. Your guide rail design should match how your fleet actually moves day to day.
Measure your current working widths and factor in the space that guide rails will occupy. We’ll ensure that rails enhance safety without narrowing your operational space beyond compliance or comfort.
Standard, Euro, and custom pallets vary in width and handling method. Guide rails should be spaced to match your pallet footprint, particularly in drive-in systems where misalignment can slow loading or damage stock.
It pays to think beyond the racking. Identify high-risk zones like blind corners, cross-traffic intersections, and shared pedestrian areas. These are key areas where guide rails can prevent near misses and improve flow.
FAQ on Adelaide guide rails
If you have wide aisles and low forklift traffic, guide rails may not be essential. But they’re strongly recommended in high-traffic, drive-in, or narrow-aisle operations where alignment and protection are more critical.
While not mandatory under all WHS codes, guide rails are often required as part of a risk management strategy – especially in narrow-aisle operations or facilities handling high volumes of mobile equipment. They also help meet obligations under the Work Health and Safety Act 2011 (SA) to eliminate or minimise risks so far as is reasonably practicable.
Most installations can be completed in 1–3 days depending on aisle lengths and working conditions. We can work outside operating hours if needed to minimise disruption.
Properly installed guide rails are low-profile and placed for minimal interference. We plan their location carefully to ensure they improve safety without restricting functionality.
Yes. Our modular systems are bolted in place (not welded), allowing for removal or reconfiguration as your warehouse evolves.
Just contact us. We’ll assess your facility and recommend the right rail height, thickness, spacing, and layout – based on your racking system, traffic type, and safety goals.
Make your warehouse safer with guide rails
When forklifts are moving fast and storage space is tight, guide rails are more than a precaution – they’re protection that pays for itself.
Call us on 1300 722 626 or request a quote now
Tell us your warehouse layout, forklift specs, and pallet dimensions. We’ll build an Adelaide guide rail system that helps keep your racking, team, and operations on track.
Need broader support? Explore our racking protection range, check out case studies, or browse our warehouse fit-out services.
Nobody knows racking like Rackman Australia
Not only do we ensure your compliance with Australian laws and insurance requirements, but we also carry our own insurance covering consultation, design, and inspections. With Rackman Australia, you can trust that your racking system is up to standard – and get back to doing what your business does best.