5 Tips to Protect Pallet Rack Sprinklers from Forklift Damage | Apex Safety Spotlight
Forklifts vs. Sprinklers: Ensuring the Safety of Your Warehouse Fire Suppression System
Protecting your warehouse and team from a damaging fire is a critical priority. An average of 1,450 warehouse fires in the U.S. annually result in hundreds of millions of dollars in direct property damage, risk the lives of workers and staff, and can grind productivity to a halt. Installing pallet rack sprinklers is one of the most effective ways to mitigate the risk and enhance warehouse fire safety.
In-rack sprinklers are fire suppression devices designed and installed within pallet racks. These sprinklers are strategically placed at various levels of the rack structure to respond quickly and directly to fires within the storage racking.
However, the constant forklift activity inherent with a pallet rack system can leave the exposed elements of your fire suppression system vulnerable to damage. Sprinkler heads and piping are at particular risk as they are secured within the storage bays. With the following tips, you can protect your exposed in-rack sprinkler equipment from damage and minimize costly repairs.
Types of In-Rack Sprinkler Systems
- Wet Pipe: A system where water is constantly present in the pipes, ready to discharge immediately upon activation, suitable for areas not subject to freezing temperatures.
- Dry Pipe: Uses pressurized air or nitrogen in the pipes instead of water, which is released first upon activation to allow water to flow into the pipes and then discharge, suitable for areas prone to freezing.
- Pre-Action: Combines features of both wet and dry systems, requiring both a fire detection event and activation of sprinklers to release water, reducing accidental discharge and suitable for areas with high-value assets or sensitive environments.
- Deluge: A system where all sprinklers connected to the piping system are open and will discharge water once triggered by a fire detection system. It is often used in high-hazard environments where rapid fire suppression is critical.
- Foam-Water: Incorporates foam concentrate into the water supply to create a foam blanket upon discharge, effectively suppressing fires involving flammable liquids or materials.
5 Tips to Safeguard In-Rack Sprinklers from Forklift Damage
Strategic Positioning and Sprinkler Head Cages
- Strategic Positioning: Placing sprinkler heads behind structural elements of the rack, such as the uprights, provides a physical barrier, reducing the risk of accidental forklift strikes to the sprinkler heads. Running the piping network behind the horizontal beams shields pipes from damage.
- Sprinkler Head Cages: Install steelsteal cages over the sprinkler head to protect against minor bumps and interference. Cages provide an added visual for forklift operators to spot and avoid sprinklers. Painting the guard a bright color also helps.
Sprinkler Head Guards: Steel guards offer multifaceted protection for sprinkler heads and lines. They serve as a sturdy barrier against impacts, deflecting force to prevent damage. Guards allow the sprinkler heads to remain visible, ensuring that they can still effectively discharge water in the event of a fire.- Proper Training: Ensure that forklift operators receive comprehensive training on safe driving practices, including awareness of the location of in-rack sprinklers and the importance of avoiding collisions with them.
- Regular Inspections: Implement a routine inspection schedule to check for any signs of damage or obstruction to in-rack sprinklers caused by forklifts. Promptly repair or replace any compromised sprinklers to ensure they remain fully functional.
While the initial investment in added protection, such as cages and guards, increases the system’s initial cost, they can ultimately save money by preventing costly damage to sprinkler systems and avoiding potential downtime during repairs.
Fire Baffles or In-Rack Sprinklers?
Depending on the rack design and combustibility of the materials stored, consider installing fire baffles in addition to or as an alternative to in-rack sprinklers. Steel fire baffles form barriers to trap heat, activate sprinklers, and hinder fire spread. They mitigate inventory loss and contain fires effectively. They are easy to install –both vertically and horizontally if warranted and conform to local fire codes.
NFPA mandates in-rack sprinklers for systems exceeding 20 feet in depth or 25 feet in height. However, meeting specific criteria allows fire baffles to serve as a cost-effective alternative to an in-rack system:
- Maintain 6” transverse flue space every 5’
- Limit depth to 20’
- Ensure 3’ 6” longitudinal flue space every 20’ for rack separation
- Install a vertical barrier every 20’ behind the rack
Full-Service Design, Installation, Inspections, and Repairs with Apex!
The Apex team delivers streamlined, full-service support for all your warehousing needs, from expert design services to ensuring the smart configuration and proper materials to satisfy fire compliance requirements. Apex professional pallet rack installers will build your system and install your fire prevention system with precision… and, when you’re ready for inspections, try our free app!
The Apex Rack Repair App empowers users to conduct thorough pallet rack safety inspections with DIY ease. Capture key specs and photos of system damage, from columns to beams. You can also schedule our certified rack inspectors to come to you and perform a thorough warehouse safety review. Using the Apex Rack Repair solutions, you receive comprehensive inspection reports and repair recommendations if needed.
Try the Rack Repair App today –download it free from or the App Store.
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