Common Types of Pallet Racking Failures and How to Prevent Them

Pallet racking can be the most space-efficient, affordable, and time-saving storage solution for warehouses and fulfilment centres.

This type of warehouse shelving allows you to stack pallets up to 12 meters high and easily access any pallet you need without having to move heavy items you don’t need.

However, because the items on selective pallet racking shelves can be so heavy and are stacked at great heights it is important that you know how to keep your pallet racking installation safe and undamaged.

Accidents from damaged warehouse racking and inefficient checks can result in dangerous situations for your stock, and more importantly, your employees.

Why is it Important to Do Proper Safety Checks and Safety Training?

The causes of pallet rack collapses are multiple and can vary from warehouse to warehouse according to the type of forklift being used, the weights on the rack shelves, the types of racks and the warehouse environment.

Although your installed pallet racking may be incredibly strong and high quality, it is still subject to heavy weights, pressures and stressors which can compromise structural integrity of not properly addressed.

If one rack collapses, this could result in injury to nearby employees, damage to equipment close by, and lead to other racks falling in a domino-like effect.

Making sure that you have your pallet racking installed safely and securely and train your employees to recognise issues quickly could stop dangerous and costly faults from developing.

That’s why it is essential that you as a business owner are aware of the issues to look out for to save costs and ensure that your pallet racking installation is a long span shelving option for you warehouse racking system.

Common Types of Pallet racking Failures and Damage

1. Forklift Collisions and Bumps

Most warehouses are busy, congested places with people and forklifts moving around the area at a speedy pace. Because of this it can be a common occurrence for forklifts to hit or bump pallets racks as they manoeuvre around them.

Although the damage may not be immediately apparent, columns may have been damaged, bent, or compromised so that they will later collapse.

Make sure to carry out regular checks for damage and immediately deal with signs of tilting, bending, and misshapen racks.

2. Cheap materials and Inefficient Installation Services

To ensure that you can fulfil your products and services as efficiently as possible you need to make sure that your warehouse storage suppliers offer pallet racking which is strong and reliable.

All your pallet racking storage shelves need to comply with AS 4084-2012 Australian Racking Standards.

So, you need to make sure not to be tempted by the false economy of ordering faulty, inferior, and cheap materials which won’t last long and require continual pallet racking repairs.

3. Installing Pallet racking Shelves on Uneven Surfaces

In order to safely store heavy loads up to 12 meters tall, the base of the pallet racking system needs to be safely and securely installed on an even warehouse floor.

Installing this shelving on bumpy, uneven ground could result in unbalanced weight distribution, extra pressure on joins, and tilted racks. All of which could pose serious health and safety risks to your warehouse staff.

4. Overloading Your Pallet Racking Shelves With Too Much Weight

If your pallet racking shelves are strong and comply to Australian standard regulations, they all have their weight limits. If you ignore the manufacturer guidelines and load the shelves with too much weight, you are risking damage to your shelves and injury to your workers.

So, it is essential that all of your forklift operators and workers have a clear idea of the volume limits of each rack and the dangers involved in placing too much weight strain on the racking shelves.

Your regular pallet racking inspections should include an assessment of the weights on each rack. And if a unit is overloaded, this should be rectified as soon as possible.

How to Prevent Pallet Racking Failures

1. Make sure your Staff is Well Trained

Your warehouse staff are going to be the people you need to rely on to safely use both the forklifts and pallet racking shelving in your location. So, you need to make sure that they are adequately trained to use the equipment to avoid unnecessary damage and safety hazards.

2. Schedule Regular Pallet Racking Inspections

You are legally required to have a professional inspection of your installed pallet racking systems every 12 months. But, if you want to make sure to catch costly issues quickly, you need to have regular checks of your shelves by knowledgeable staff.

Not only is this important from a health and safety standpoint, but it will also help you to spot issues quickly before having to pay for the costly repairs of larger problems that can develop.

3. Make Sure That You Use a Reliable Pallet Racking Supplier and Installer

To make sure to avoid problems later down the line, you need to make sure to source your pallet racking from a reputable supplier.

You should also make sure that the pallet racking installation is completed by experienced installers who know how to safely secure the shelves in your warehouse space.

Takeaway

Pallet racking installations can be incredibly space and time savers for companies across a variety of industries. But in order to make sure your pallet racking shelves are safe and secure, you need to be aware of what failures and damage to look out for.

Regular checks of pallet racking shelves are essential, as is proper training of warehouse staff. Ensuring you keep on track of any new damage, tilting, or rust on pallet racking installations will ensure that this storage solution remains viable in the future.

For more questions about pallet racking inspection, please contact Multiple Storage Solutions at 03 8390 4483.