Case Study: GXO Thrapston (Primark)
When a large-scale distribution centre in Thrapston found itself operating a pallet racking system that had reached end-of-life support — with no viable supply of compatible spare parts — the conventional options were stark: endure ongoing downtime and condemned bays, or commit to a full racking replacement programme at enormous cost and disruption. Goliath™ offered a third way.
Extending the Life of an Obsolete Racking System
The Problem
The site operates a PSS pallet racking system — a system that, while structurally sound and fit for purpose in day-to-day use, has reached the point where OEM replacement components are no longer readily available. For a busy distribution operation, this creates a compounding problem:nnDamaged uprights cannot be replaced like-for-like because compatible parts are no longer manufactured or stocked. Condemned bays accumulate over time, steadily reducing usable storage capacity. Full system replacement is prohibitively expensive and operationally disruptive. Temporary fixes and safety workarounds create compliance risk and compromise structural integrity.nnThe only long-term answer is one that makes the supply of OEM spare parts entirely irrelevant — and that is precisely what Goliath™ delivers.
Obsolete racking systems are a growing challenge across UK warehousing. As systems age out of manufacturer support, operators face a choice between expensive replacement programmes and ongoing disruption from condemned bays. Goliath™ removes that choice entirely.
The Solution: Goliath™
Goliath™ was designed from the outset to be universally compatible with all types of pallet racking systems manufactured and installed across the UK and Europe. This makes it uniquely suited to the challenge of obsolete or legacy racking — systems where the original manufacturer may no longer supply parts, or where compatible components have become scarce and costly.nnGoliath™ replaces only the most vulnerable section of the upright — the lower 700mm where 85% of all racking damage occurs — restoring full structural integrity. It is independently accredited to BS EN 15512:2020 + A1:2022, BS EN 15635:2008, and Industry Codes of Practice, and backed by a Lifetime Impact Warranty.nnIn short, Goliath™ transforms a problem that cannot be solved through conventional procurement — because the parts simply do not exist — into one that can be resolved on-site, in under half an hour, with zero OEM dependency.
Goliath™ eliminates the need for OEM spare parts entirely. It is the spare part.
Phase One: 60 Units Installed and Operational
The first phase of this installation saw 60 Goliath™ units fitted across the PSS racking system. Each unit was installed without disruption to the surrounding racking structure, restoring condemned bays to full operational use and returning usable storage capacity that had effectively been written off.nnThe results were immediate. Bays that had been taken out of service due to damaged uprights were back in use, structurally sound, independently certified, and covered under warranty — all without a single OEM replacement part being sourced.
Phase Two: A Further 50 Units on Order
The success of the initial installation has prompted a second phase order of a further 50 Goliath™ units, extending the repair programme across additional bays and consolidating the site's long-term racking maintenance strategy. This follow-on order reflects the confidence the operation now has in Goliath™ as its primary racking repair solution.
Key Technical Specification — Goliath™ Upright Repair Kit
System compatibility: Universal — all pallet racking types including legacy and obsolete systemsnMaterial: 6mm structural steelnAccreditation: BS EN 15512:2020 + A1:2022 | BS EN 15635:2008 | Industry Codes of PracticenInstallation time: Under 30 minutes per uprightnWarranty: Lifetime Impact WarrantynOEM parts required: None
The Results
Across both installation phases, Goliath™ will have delivered 110 permanent racking upright repairs at a site whose racking system was, by conventional measures, beyond its maintainable life. The PSS system is not being replaced — it is being extended, indefinitely, by a solution that requires no manufacturer support and no ongoing procurement headache.
110 Total Units
Across both installation phases, including 50 on order
0 OEM Parts Required
Complete independence from the original manufacturer
Under 30 Minutes Per Upright
No specialist equipment required
Lifetime Warranty on Every Repair
Each unit protected in perpetuity
The success of the initial 60-unit installation prompted a second phase order of a further 50 Goliath™ units, extending the repair programme across additional bays. This reflects the confidence the operation has in Goliath™ as its primary racking repair solution — not a temporary fix, but a permanent one.
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