Warehouses use pallet racks to store most of their inventory because they are large and built well. Unfortunately, there are a variety of ways that pallet racks can become damaged. Forklift trucks cause the most damage, as they are often used to retrieve and store racks. Regardless of how they are damaged, whenever a pallet rack system is compromised, it becomes unsafe for employees to use. Your pallet rack system can be evaluated for damage so that we can make recommendations for replacement or repair of the damaged rack.
If the racks are ignored, rack overloading, coupled with slight damages, could potentially have a snowball effect that leads to a major collapse. Workers can sustain injuries, or even die, as a result of pallet rack collapses that carry thousands of pounds worth of inventory.
Inventory damage could set your business back thousands of dollars, and your warehouse would likely face operational disruptions due to repair work.
A pallet rack inspection should be conducted regularly to prevent these situations from occurring. One of the best ways to ensure a safe workplace is by keeping racks well-maintained through quality inspection. Every business that operates mechanical lifting equipment should inspect and document the safety of its pallet racks.
The following offer some tips on when and how often a pallet rack inspection should be performed to check for damage, along with some preventive actions that should be taken to protect the racks.
Weekly Walkthroughs
Weekly walkthroughs and regular inspections help to spot and identify slight and minor damages due to forklift collisions or wear and tear, which aren’t often reported by drivers. Weekly inspections also highlight minor repairs so they can be addressed in a timely manner to avoid larger risks down the road.
Inspections and walkthroughs can be carried out quickly, are inexpensive, and cause little to no disruption to your overall warehouse operations.
Yearly Pallet Rack Inspections
Yearly professional pallet rack inspections should be performed to record your racks’ condition. This ensures that your racking system is being properly maintained, and that the loads and material handling equipment are both compatible with one another. You will be able to identify any repairs that need to be made so your employees will have a safe work environment, which will keep your investment protected and extend the life of your pallet racks.
If a forklift accidentally strikes a beam or a column, it should be inspected immediately. Beams can become knocked out of their fastened positions and damaged easily from overloading or minor fork collisions. A small dent in the bottom of a rack can lower the rack’s upright capacity.
To a significant degree, a racking system’s uprights depend on how the beams are spaced. A racking system’s structural integrity can be weakened if there are slight bangs or collisions. You should inspect and repair minor dings after a small accident to avoid potential safety risks.
Following OSHA Inspection Guidelines
The Occupational Safety and Health Administration (OSHA) was formed by the U.S. Department of Labor to keep workplaces and employees safe. While OSHA doesn’t have any specific guidelines for rack inspections, its general clause addresses concerns that affect material handling methods such as racks and storage.
Section 1910.176 in the OSHA handbook requires all mechanical equipment to be handled properly, all aisles and passageways to be appropriately marked, and safe clearances. In addition, your material handling system must be set up correctly to avoid accidents. The general clause also states that your items should be stored safely so that they do not collapse or slide. Storage areas should not contain any materials that could contribute to hazardous working conditions such as trips or falls.
Preventive Measures
To decrease the likelihood of your pallet racks becoming damaged, you should take these preventive actions into consideration:
- Pallet Rack Column Protectors: These pallet rack protectors are free-standing and are mounted in front of a 3” or 4” pallet rack upright frame. They prevent pallets from becoming damaged by forklift impacts.
- Guard Rails: Guard rails can be installed to minimize damage to your lower racks. These heavy-duty rails provide excellent storage equipment and racking protection.
- Wide Aisles: Widening your aisles will make it easier for lift trucks to maneuver throughout your warehouse facility.
- Forklift Driver Training: Your forklift drivers should receive training regarding speed limits around each aisle, and should also be given procedures on how to back away from the racks without causing damage to them.
Do you need to have your pallet rack system evaluated for damage by an expert? We can make recommendations for repair or replacement of damaged rack.
