The most common pallet rack failures and how to avoid them.
Warehouse owners and managers shoulder a major responsibility for warehouse rack success or failure. Structural maintenance and regular inspections are the best way to prevent these common rack failures.
Pallet racking failures are more common than you might think. Even with the advanced engineering of today’s racking systems, small errors can cause major collapses. Identifying and addressing these risks can prevent accidents, save costs, and ensure a safer working environment for your team.
#1
Overloading Racks
Overloading or unevenly distributing weight on pallet racks can lead to serious issues. Racking systems are built to handle specific load limits, and going beyond these can strain beams, welds, and uprights.
Solution
Always follow manufacturer guidelines and clearly label the maximum load capacity on each section. Regularly checking load capacities and ensuring weight is evenly spread across the beams helps prevent excessive stress on the system and reduces the risk of collapses.
#2
Improper Installation
Incorrectly installed racks may be unstable and prone to tipping. Pallet Rack System configuration (shelf beam levels, bracing pattern, etc.) is carefully engineered to satisfy operational requirements. Changes in shelf elevation, for example, can reduce column capacity and lead to system failure.
Solution
Ensure professional installation and regular inspections to verify structural integrity.
#3
Rack Damage
Bent or damaged uprights and beams can weaken the entire pallet racking system, increasing the risk of failure. Lift equipment abuse is the leading cause of rack system failure and collapse. Whether from operator mistakes or equipment malfunctions, forklifts can inflict significant damage on rack columns and beams. Repeated impacts, particularly at the base of columns, can weaken the structure and increase the chances of a rack collapse.
Solution
Regularly inspect racks for signs of damage and replace any compromised components immediately. Consistent training and the use of modern impact prevention systems are essential to minimize this risk.
#4
Poorly Secured Loads
Improperly stacked or unsecured pallets may fall, endangering workers and products. Warehouse owners and managers may choose to understate actual capacity requirements in order to reduce rack equipment costs. Cutting corners is a very dangerous mistake that often ends up costing exponentially more than doing it right the first time.
Solution
Train staff on proper stacking methods and consider adding safety accessories like wire decking and pallet supports.
#5
Forklift Collisions
Improper forklift training leads to rack damage as discussed above. Over time, impacts from poor forklift navigation can seriously compromise the structural integrity of your warehouse rack.
Solution
Install protective barriers around high-traffic areas and ensure forklift operators are trained to navigate safely around the racking.
#6
Equipment Error
Pallet racking systems are designed for integration with specified lift equipment. An equipment change can result in unforeseen misuse and rack damage. For example, using standard fork trucks or pallet jacks in a Very Narrow Aisle (VNA) or wire guided system will cause damage in areas where abuse-resistant measures Don’t exist.
Solution
Hire a professional warehouse manager to train your staff in proper equipment use.
#7
Change in Opertation
Rack failure can also occur when business requirements mandate a new operational procedure outside of the original plan.
Solution
Warehouse design and layout should be completed and finalized before any racking is installed or relocted.
#8
Mixing Components
Mixing components from various manufacturers is another version of cutting corners to save money. There’s no assurance that a combination of manufacturers’ components will perform to original system design specifications.
Solution
Always follow manufacturer guidelines and only use recommended parts and components.
How do you prevent pallet rack failure?
Safety should always be a top priority in any warehouse. By understanding and mitigating these common pallet racking hazards, you can create a safer, more productive workplace for your team. If your pallet racking system is in jeopardy of failure or collapse, there are four steps you can use to reduce risk and ensure rack safety.
Pallet Rack Inspection
The first step is to conduct a thorough pallet racking inspection. This means You’ll need to locate initial design drawings and calculations, document current elevations and rack layout, determine if the current configuration is structurally sound, examine the full extent of existing rack damage and plan to repair or replace your racks. It’s important to keep a set of drawings reflecting your current rack configuration. This is a requirement of the Rack Manufacturer’s Institute (RMI) as well as the Canadian Standards Association (CSA).
Warehouse Training
The next safety step requires that you develop a driver-training program with accountability written into that process. It’s also recommended that you establish an on-going rack safety audit program and that you install and maintain rack capacity plaques in several obvious and clearly visible locations. The good news is with the proper rack maintenance program you will not only reduce the risk of rack failure but also extends rack system life.
