Safety Insert for Pallet Racking

Safety Insert: store half pallets safely

The Safety Insert (also used as a tunnel guard, sometimes called a tunnel protector, or as a half pallet platform) is installed between the horizontal load beams. By closing the open gap between the beams, it provides a stable bearing surface for smaller or special-size pallets and helps prevent pallets from tipping or falling through if they are placed incorrectly. In many warehouses it is also referred to as a half pallet insert, because it makes half pallet storage practical in standard pallet racking.

Why tunnel protection matters in daily operations

Any warehouse that runs multiple shifts knows how quickly a small disruption spreads. A pallet that drops into a tunnel can block a lane, delay picking and replenishment, and force operators to work around a temporary hazard. The aim of a tunnel guard is straightforward: keep the travel route clear by preventing pallet drop in the first place. By adding a support element between the beams, you reduce the chance that a pallet will slip into the tunnel due to an uneven load, damaged pallet base, or a slight misplacement during storage.

Half pallet storage without extra support frames

Standard pallet racking is built around common pallet sizes, but real-life logistics is rarely that tidy. Half pallets and other special-size pallets are used for campaign goods, spare parts, export packing, and staged production material. Without an insert, these smaller pallets can sit insecurely on the beams or require separate adapter frames. With a Safety Insert, you can support a half pallet directly in the pallet racking level, using the existing beams. In many layouts, half pallet handling also helps you use space that would otherwise stay empty at the front of a pallet position. When planned correctly, this can increase the number of usable pallet locations.

Durable construction for industrial use

The element is made of galvanised steel, chosen for warehouse conditions where surfaces are exposed to moisture, temperature changes and occasional chemical splashes. It is suitable for demanding environments, including cold stores. The standard element depth is 1050 mm, which fits the most common pallet racking depths without modifications. The insert is designed to spread the load evenly across its surface; a typical evenly distributed load capacity is 1000 kg. Always follow the load notices for your racking system and keep the total bay loading within the permitted limits.

Key benefits you can see on the floor

Safety accessories only earn their place when they make day-to-day work smoother. A Safety Insert delivers practical advantages that operators and supervisors notice quickly:

• Drop prevention: helps stop pallets from falling into forklift tunnels and reduces the risk of blocked routes and incidents.
• Support for half pallet and non-standard pallets: creates a stable base on the beam level, making storage safer when pallet dimensions vary.
• Cost-effective retrofit: adds support between existing beams, without needing to change the beam set-up or add separate external frames.

Compatibility and choosing the right version

This Safety Insert is available for both EUR pallet and FIN pallet sizes. The insert profile is intended for common pallet racking designs when the frame depth is 1050 mm. If you run mixed pallet formats, it is worth standardising the insert selection by rack section, so operators can store the right pallets in the right lanes without guesswork. As with any racking accessory, compatibility depends on the beam type and clearances in your system, so match the insert to your racking dimensions before installation.

Installation and use

The insert is mounted between the load beams at the required level. Once installed, it stays in place and provides a continuous support surface where the pallet would otherwise span an open gap. In daily use, the benefit is simple: forklift operators can place half pallet loads and special-size pallets onto a supported surface, and pallets are less likely to drop into the tunnel if a placement is slightly off.

Maintenance, inspection and EN 15635 routines

Galvanised steel is essentially maintenance-free in normal warehouse use. Include the Safety Insert in your routine rack inspections, especially in high-traffic zones. If an insert is bent, twisted, or shows clear signs of overload, it should be replaced. This supports the intent of EN 15635 guidance, where damaged components are removed from service to keep the rack structure and working area safe.