RackNets™ safety netting systems have become a trusted choice in many UK warehouses, helping to reduce the risk of items (like loose stock or even full pallets) falling from racking and causing injury or damage.
Developed by ELAN, RackNets™ 3.0 provides a flexible and robust solution for typical warehouse environments, including protection against pallets weighing up to 1000kg. For sites that need an even higher level of protection, RackNets™ 5.0 offers the same core design as 3.0, but with enhanced strength and durability for more demanding applications.
In this guide, we’ll walk through how to install both versions, including what you’ll need, key steps to follow, and a few practical tips to make the process easier and more efficient.
Stage 1 – Fitting Main Brackets
Each section of net must have a main bracket in each of its four corners.
Main brackets must be fitted to the top of struts. Some will require intermediate brackets, and you should always refer to the system drawing supplied. A main bracket may be a corner for more than one section of netting.
Main brackets must be fitted with the side plate facing the correct way. This sets up additional support and minimises twists on the end of uprights. Brackets are designed to take loads vertically.
- For a two-bay installation, these are the correct positions, with both side plates facing inwards for maximum support. In this situation, a main bracket will also be placed on the central strut, positioned as shown.
- For a multi-bay installation, see correct positions below. Note the position of the bracket faces.
- Any brackets that have bracing attached must face into the rack, as this uses the brackets’ design to provide maximum support.
Main brackets are fitted to the racking struts using two M10 nuts, M10 bolts, and M10 washers. All these fittings are the same size for all struts.
Main brackets are supplied with two rectangular Apex packers to provide support for the M10 serrated nut inside the strut and to prevent the nuts pulling through the enlarged coughing slot.
Brackets intended for use on Apex pallet racking are supplied with an additional six Apex packers to prevent damage to the louvers and to support the full width of the bracket.
Measure down from the centre of the top cable to ensure the bottom brackets are in the right place for the net. This will be detailed on the supplied installation drawing.
Stage 2 – Fitting Side & Intermediate Brackets
Side brackets are fitted on the end upright at a spacing of approximately 1.25 metres to support the vertical cable. This spacing will be dependent on where beam levels are located.
Intermediate brackets are fitted:
- To the top of all vertical struts where there is no main bracket
- To the bottom of all vertical struts
Side and intermediate brackets can be fitted before or after the cables have been attached.
- Side brackets: If there are problems fitting two bolts, side brackets with Apex struts can be secured with one bolt, as the raised louvers will prevent rotation. No packers are required.
- Intermediate brackets: With Apex struts, three packers must be used between the bracket and shelving uprights to prevent damage to them. A packer should also be fitted to the rear.
With non-Apex struts, packers are only required between the nuts and the strut. This applies to both the side and intermediate brackets.
Stage 3 – Fitting Bracing
Bracing must be fixed to the top of the two end bays. Special instructions may require additional bracing to be fitted.
- Lay the bracing bars on the floor beneath the racking to get the correct length.
- Fix each pair of bracing bars with three M8 x 20 mm nuts, bolts, and washers – two horizontally and one vertically.
- Fix the joint bracing bars to the main brackets using M8 x 55 mm nuts, bolts, and washers.
Stage 4 – Fitting Horizontal Cables
Cables come in pre-cut and labelled lengths. Each cable has an identifying label. There is no need to cut any cables.
- Check plans and spec sheets to confirm which cables are to be used in which location.
- Fix the cable to the left-hand side main bracket by passing the pre-fixed eye to the outer horizontal hole and fastening using the supplied locking nut (do not tighten the nut at this stage).
- Thread the cable from left to right, passing through the eye of any main or intermediate brackets fitted.
As both holes of the right-hand main bracket will be allocated to the bracing and the vertical cable bolt, you have two options:
Option 1 – Vertical Hole
- Enlarge a hole in the bracing and use the eye bolts from the vertical cable to secure the bracing.
- Pass the cable through a cable fixer, loop through the free hole at 90 degrees to its path of travel, and then back through the second hole of the cable fixer.
- Position the cable fixer between 30 and 45 cm from the main bracket.
- Make sure the spring inside the cable fixer is flat – this helps the cable slide through easily.
Option 2 – Horizontal Hole
- Pass the cable through the cable fixer, then through one of the main bracket’s horizontal holes.
Loop it back through the second hole of the cable fixer. - Position the cable fixer 30–45 cm from the main bracket.
Pull the cable hand tight and lock the cable fixer with the Allen key. Cables do not have to be very tight, as the whole structure takes the strain. Over-tensioning can distort the main brackets and may twist the frame.
- Tighten the eye bolt to remove some of the cable sag.
- Make sure the cable sits level but is not over-tensioned.
- Tidy surplus cable using cable ties.
Tensioning multiple cables along a single run:
- Take care to ensure brackets are only loaded in the permitted direction.
- In the diagram, cable B should be tightened first, as the brackets are facing the right way for maximum strength.
- Cable A can then be tightened without putting pressure on the central bracket, which is the anchor point for two cables.
- Never attempt to pull an incorrectly loaded bracket straight by over-tensioning the next cable.
Stage 5 – Fitting Vertical Cables
This process is similar to Stage 4 (fitting horizontal cables). Cables come in pre-cut and labelled lengths. Each cable has an identifying label. There is no need to cut any cables.
- Check plans and spec sheets to confirm which cables are to be used in which location.
- Fix the cable to the left-hand side main bracket by passing the pre-fixed eye to the outer horizontal hole and fastening using the supplied locking nut (do not tighten the nut at this stage).
- Pass the cable to the bottom main bracket, threading through any side brackets installed.
- The cable should pass through one hole in the cable fixer, then through one of the side holes of the bottom main bracket. Loop it round at 90 degrees to the direction of travel.
- It then goes back through the second hole in the cable fixer.
- Make sure the spring inside the cable fixer is flat – this helps the cable slide through easily.
Pull the cable hand tight and lock the cable fixer with the Allen key. The cables do not have to be very tight, as the whole structure takes the strain. Over-tensioning can distort the main brackets and may twist the frame.
- Tighten the eye bolt to remove some cable sag.
- Make sure the cable sits level but is not over-tensioned.
- Tidy surplus cable using cable ties.
Stage 6 – Fitting Nets
- Check the label on the net to make sure it’s the correct one.
- Make sure you know which side is the width and which is the height – nets must be fitted the correct way.
- Carabiners are used to fix the net to the cable.
- Connect carabiners to the outer edge of the net, not the main netting. The outer edge is reinforced to provide strength in the system.
- Fit two carabiners at each corner.
- Fit the next carabiner at five net spaces, then at six net spaces. Continue this five–six spacing until you reach the end. The last carabiner may need a different number of spaces – use your judgement to spread the carabiners evenly.
For multiple-net installations:
Two nets: place carabiners on three sides of the first net, and on all sides of the second net. The middle of each of the two nets will share one set of carabiners.
- Three nets: two nets will have carabiners on three sides; the third net will have carabiners on four sides. The process is the same for other multi-net installations.
- Attach the two corner carabiners to the vertical and horizontal cables. You may pass one of them through the cable loop.
- Connect the top of the nets to the top cable. You can connect some of the vertical carabiners while the lift is in the corner position.
- Fit the two sides, leaving the bottom until last.
On the bottom run:
- Fix carabiners to the ends first, then the centre – this makes fixing the rest easier.
Make sure the cables pass through all side and intermediate brackets.
If shortening nets is required (e.g. due to an error in ordering or changes to the racking):
- Do not cut the nets.
- The edges are made to take the strain and are the only part that should be connected to the cables.
- To shorten a net: fix the carabiners, then roll the net, passing the carabiners through the net each revolution.
- If unsure how much a net can be rolled, contact installation support.
To support the net, cable ties are looped around the face of the strut and the net. The net is not pulled tight against the racking. Cable ties are positioned at each beam connection – one above and one below the connector.
All RackNet systems are designed for specific racking installations – always refer to the supplied installation drawing. Any alterations to the layout must not be made without the approval of ELAN Europe.
End of Installation Guide
By following these instructions carefully, you can ensure optimal safety and functionality for your RackNet system. For any assistance or if you encounter any issues during installation, please contact us for guidance.
