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Single Height Warehouse Guard RailAdd-On Kit: Expand Your Safety System Without Starting Over



Single height heavy duty warehouse guard rail add-on kit with post, rail and hardware

If your warehouse already has a guardrail system in place but certain areas still feel exposed rack aisle ends, machinery perimeters, pedestrian crossing points you don't need to rip out what's already working. The Single Height Heavy Duty Warehouse Guard Rail Add-On Kit from Guardrail Online is designed to extend your existing safety barrier line, one section at a time, without disrupting operations.

This guide covers exactly what's in the kit, who it's for, where it works best, and why it's the smarter choice over buying a full starter system when you just need to fill the gaps.



What Is a Guardrail Add-On Kit?

A guardrail add-on kit is a single expansion unit — one post, one rail, and all the hardware you need to attach it to an existing guardrail line or start a new section from an existing anchor point.

Unlike a starter kit (which includes two posts and one rail to begin a new guardrail run), the add-on kit assumes you already have at least one post installed. It slots directly onto your existing system and extends protection in any direction.

Think of it like adding a new link in a chain. Each add-on kit adds one more section of protection, using the same post spacing, the same rail height, and the same safety yellow finish so your entire barrier line looks and performs consistently from end to end.



What's Included in the Kit

Every Single Height Add-On Kit ships with everything needed for a complete, code-ready installation:

1 x Rail (your length choice — 2ft to 10ft)

  • Material: Galvanized steel, 11-GA (0.118″ thick)

  • Rail height: 12.2″ (17.61″ installed height)

  • Part numbers: A0010 (2ft) through A0001 (10ft)

  • Exact lengths: 19.28″ to 115.28″

  • Weight range: 16.57 lbs (2ft) to 76.59 lbs (10ft)

  • Finish: Pre-galvanized + powder-coated safety yellow (RAL 1023)

  • Impact rating: 10,000 lb at 4 mph when properly installed

1 x Post (19″ Single Height, Centred)

  • Steel: 4.72″ x 4.72″ x 3/16″ thick

  • Base plate: 10″ x 10″ x 5/8″ thick, welded

  • Rail height achieved: 17.61″

  • Weight: 35.3 lbs

  • Finish: Pre-galvanized + powder-coated safety yellow (RAL 1023)

1 x Rail Hardware Kit

  • 4x M12 x 1.75-160mm hex head bolts (Grade 8.8)

  • 8x M12 washers (Grade 8.8)

  • 4x M12 hex nuts (Grade 8.8)

1 x Post Hardware Kit

  • 4x 5/8″ x 5″ wedge anchors (post-to-concrete)

  • 1x black polyethylene post cap

  • 8x yellow polyethylene hole plugs

No separate hardware orders needed. No missing bolts. Everything is in the box.



Rail Length Options and Weights

Choose the rail length that matches your spacing needs. Post center-to-center spacing equals your selected rail length plus 4 inches.

Rail Size

Part No.

Post C-to-C (in)

Exact Length (in)

Weight (lbs)

Price

2ft

A0010

24

19.28

16.57

$167.00

3ft

A0009

36

31.28

24.07

$192.00

4ft

A0008

48

43.28

31.57

$216.00

5ft

A0007

60

55.28

39.10

$240.00

6ft

A0006

72

67.28

46.58

$257.00

7ft

A0005

84

79.28

54.10

$275.00

8ft

A0004

96

91.28

61.58

$290.00

9ft

A0003

108

103.28

69.10

$304.00

10ft

A0001

120

115.28

76.59

$314.00

Note: Nominal length is measured center-to-center of posts.



Who Is This Kit For?

The add-on kit is built for three types of buyers:

1. Existing Guardrail Online customers Already running our single height starter kits? This add-on is designed to integrate directly with your existing posts and rails — same steel spec, same finish, same bolt pattern. No adapters, no modifications.

2. Facility managers expanding coverage You know the areas that need guardrails but can't justify replacing your whole system. The add-on lets you fill specific gaps — one aisle end, one machine perimeter, one crosswalk — without touching anything already working.

3. Safety contractors and installers Running a project that needs flexible section sizing? With 9 rail lengths from 2ft to 10ft, you can match the exact floor dimensions of any layout without cutting rails or forcing awkward spacing.

Are you a dealer or installer? Contact us for trade pricing on bulk orders.



Where Does the Single Height Add-On Kit Work Best?

Single height guardrails — with a 17.61″ installed rail height — are the right choice for areas where:

  • The primary hazard is forklift impact at lower body/base level

  • Pedestrian sightlines need to be maintained over the barrier

  • You're protecting rack bases, equipment legs, or aisle boundaries — not elevated platforms

Here are the four highest-value installation zones:

Rack Aisle Ends

The most common installation point. Forklifts approach rack uprights repeatedly during loading and unloading — even minor, repeated contact causes cumulative damage to rack bases and compromises structural ratings over time. A single height add-on section at each aisle end absorbs that impact before it reaches the rack.

Pedestrian Walkway Boundaries

Single height barriers create a clear physical line between foot traffic and vehicle lanes without blocking visibility. Forklift operators can see over the rail; pedestrians can see approaching vehicles. It's the right balance between protection and sightlines in shared-use areas.

Machinery and Equipment Perimeters

Control panels, conveyor legs, compressors, and charging stations all have unprotected bases that sit in the path of forklifts and pallet jacks. A single height rail section around the perimeter stops accidental contact before it causes equipment damage or downtime.

Conveyor and Packing Station Edges

Packing stations and conveyor lines operate close to forklift traffic in most DCs. A low-profile barrier at floor level keeps vehicles out of the work zone without interrupting material flow or creating overhead obstruction.



Single Height vs Double Height: Which Do You Need?

Not sure if single or double height is right for your application? Here's the quick guide:

Situation

Single Height

Double Height

Protecting rack bases and aisle ends

✅ Yes

Optional

Pedestrian walkways where sightlines matter

✅ Yes

Not recommended

Protecting tall equipment or full machinery height

❌

✅ Yes

Mezzanine edges or elevated platform protection

❌

✅ Yes

High-speed forklift zones needing full-body coverage

Optional

✅ Yes

Budget-conscious expansion of existing low-level system

✅ Yes

❌

For most rack protection, walkway separation, and equipment perimeter applications single height is the right call. For full machinery protection or higher-impact zones, consider our Double Height Guardrail System.



Why Guardrail Online's Add-On Kit Outperforms Generic Alternatives

Not all add-on kits are equal. Here's what makes ours different:

Dual-layer finish pre-galvanized AND powder-coated Most budget guardrails are powder-coated only. Our system applies galvanization first, then powder-coating on top. This dual-layer approach significantly extends the barrier's service life, especially in facilities with moisture, wash-down zones, or temperature swings.

Grade 8.8 hardware throughout Every bolt, nut, and washer in the kit is Grade 8.8 the same grade used in structural steel connections. Lower-grade hardware loosens under repeated impact and vibration. Ours holds.

Real engineering documentation Our rails come with full engineering drawings (Drawing No. CRA001, Rev. 2, approved April 2026) covering exact dimensions, weights, post spacing, and surface treatment specs. If your facility requires documentation for safety audits or OSHA compliance files we have it.

Modular and future-proof Our system is designed to grow with you. Add sections as your layout changes. Replace damaged sections without touching the rest of the line. The same post and rail design runs across our entire single height product range.



Installation Overview

The Single Height Add-On Kit is designed for straightforward installation without specialized equipment:

  1. Mark anchor points — Post center-to-center equals your rail length plus 4 inches

  2. Drill concrete — 5/8″ diameter holes for wedge anchors (anchor embedment depth per hardware spec)

  3. Set posts — Torque wedge anchors to manufacturer specification

  4. Attach rail — Connect rail to post using 4x M12 bolts per rail connection, Grade 8.8 hardware

  5. Install caps and plugs — Black polyethylene post cap + yellow hole plugs on all unused holes

  6. Inspect — Verify all connections are tight and rail is level before returning area to service

Full installation PDF available on our product pages. For complex layouts or multi-section projects, contact our team for pre-sales support.



Pricing and Ordering

The Single Height Add-On Kit is priced by rail length:

  • Starting at $167.00 (2ft rail)

  • Up to $314.00 (10ft rail)

  • Ships across all 48 contiguous US states

  • 12-month warranty on all components

  • Trade pricing available for dealers, installers, and contractors

Need to start a new guardrail run from scratch? Start with the Single Height Starter Kit ($273–$420) which includes two posts and one rail.

Need just a post? Order the Single Height Post Kit ($106) separately.



Frequently Asked Questions

Can the add-on kit connect to my existing Guardrail Online starter kit?  Yes the add-on kit is designed to integrate directly with our single height starter kit. Same post spec, same rail bolt pattern, same finish. No adapters needed.

What's the difference between the starter kit and the add-on kit? The starter kit includes 2 posts and 1 rail everything needed to begin a new guardrail run. The add-on kit includes 1 post and 1 rail for extending an existing run. If you're starting from scratch, begin with the starter kit and use add-on kits to extend.

Can I use this kit outdoors?  Our system is designed for indoor warehouse use. Outdoor installation is possible but will reduce lifespan due to moisture exposure. Contact us for outdoor application guidance.

What concrete anchor is used?  4x 5/8″ x 5″ wedge anchors are included. These are designed for solid concrete floors. Do not install on cracked, damaged, or hollow concrete without consulting a structural engineer.

Do you offer volume discounts?  Yes trade pricing is available for dealers, contractors, and bulk orders. Contact us to set up a trade account.

How long does shipping take? We ship fast across all 48 contiguous US states. Contact us for current lead times on your order size.



Ready to Extend Your Warehouse Safety System?

The Single Height Heavy Duty Warehouse Guard Rail Add-On Kit is the fastest, most cost-effective way to close the gaps in your existing safety barrier layout without downtime, without over-engineering, and without replacing what's already working.


Guardrail Online LLC Dallas, Texas. Heavy-duty warehouse guardrails shipped across all 48 contiguous US states. 12-month warranty. Trade pricing available.


 
 
 

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