Pallet racks in most warehouses take lots of abuse on a daily basis, which is why damage to pallet racks is more significant than people actually realize. The cost to repair a pallet rack is high enough, and replacing a rack is even more expensive. Downtime and product loss are also costly. Even worse are the serious injuries workers can sustain due to damaged racks.
Pallet racks can only take so much wear and tear, even the toughest of racks, which is why it’s so important that warehouses put damage protection procedures and good safety protocols into place to minimize damage and help prevent accidents.
The following is a list of the main culprits of pallet rack damage and how it can be prevented:
- One of the leading causes of pallet rack damage is forklifts. Even though the immediate collapse of a rack isn’t very likely, if a forklift operator has trouble avoiding the pallet rack, its structural integrity could lead to eventual failure.
- Another common, and often dangerous, cause of pallet rack damage is an improperly loaded rack. This includes loads that are too heavy for frame and beam capacities and loads that are unevenly distributed.
- Severe environmental conditions can cause heavy amounts of wear and tear on storage rack systems. Extremely wet conditions, outdoor storage, and freezer or refrigerated storage are some examples of intense environmental conditions that can cause extensive damage to pallet racks.
Proper Forklift Training
Employee forklift training should be your top priority. Make sure that the forklift drivers you are employing are certified, and require them to complete an annual safety course approved by OSHA. Each warehouse employee should have knowledge and training regarding the racking system, including how to properly maintain it.
The Right Racking for the Right Load
For any items you intend to store, you must select the appropriate racking capacity. If your needs change later on in the future, it may be worth your while for you to invest in higher-capacity racking. Make sure the racking you select is the proper type for your warehouse environment. For cold storage, wet environments, outdoor applications, or possible forklift abuse, we recommend structural racks.
Signage & Clear Aisles
Make sure that your load ratings are plainly visible. Whenever new SKUs are introduced, capacity issues can become a problem, which is why you should ensure that the weights of each new load are inspected and the capacities of the beams and upright frames have been confirmed. Clear visibility is a key factor in forklift safety. Other factors that contribute to driver awareness, and which are also key to preventing damage to forklifts, include excellent back-up alarms, mirrors, lighting, and other devices.
Keeping aisles clear is also important in order to maintain forklift safety. Any aisle that’s cluttered with pallets and other debris, or an aisle that’s too narrow, can increase the likelihood of an accident.
Rack Protection – More than an Accessory
Rack protection products are available and are recommended in order to keep racks safe. The products are a bit costly, but in the long run, they’re cost-efficient because they can prevent significant damage. Bollards, end-of-aisle guards, and post protectors are among the different rack protection products you can choose from.
Regular Rack Inspections
Racks should also be inspected regularly by qualified professionals. Pallet rack inspections are crucial to regular warehouse safety procedures. Additionally, employees should be trained on how to perform frequent visual inspections and walkthroughs.
Before a serious accident unfolds, make sure that you replace or repair any damaged components of a pallet rack immediately. Regular in-house and professional inspections will help you recognize possible issues early on, which will prevent accidents from occurring.
Through proper planning, training, and execution of safety protocols and products, most accidents can be avoided easily.
