Most rack damage happens low on the front column. A repair kit replaces just that section, usually without unloading the rack.
Most forklift damage hits low on the front post of an upright. The rest of the frame is usually still in good shape. When the damage is low and only on the front column, a repair kit is the faster, cheaper fix. We cut away the damaged section and replace it with a new bolted base. In most cases, the rack stays loaded while we work.
Repair is the better choice for tall or custom uprights, since new ones cost a lot to buy and ship. It also makes sense for mid-row hits, where a kit beats unloading the whole row. And if many uprights have similar damage at the same height, one kit design can cover all of them. Replacement is better when the damage is heavy or spread across many heights, or when uprights are short and standard. Not sure which you need? We will send a representative to survey the rack and count exactly which uprights need which fix.
Request an on-site damage surveyWe cut away the damaged lower section of the upright and replace it with a tubular front post. This is the simplest fix when the damage is at the bottom of the column.
The replacement leg slants inward. This gives forklifts more room to move when loading and unloading the rack. It is a common choice at spots that keep taking hits.
Column protectors and safety columns keep the repaired upright from taking the next hit. If a protector is already damaged, check underneath it. The rack behind it may be damaged too.
Depending on what you are storing, the rack may not need to be unloaded. Lighter material that is properly secured can stay put while we do the repair. For heavy or overhanging objects, we will ask you to unload the racks for safety.
We unanchor the upright from the floor. Then we attach a jack through either the side holes or the front teardrops, depending on the type of racking you have. We lift the upright about 1 or 2 inches off the ground and cut off the bottom. Based on where the damage sits and how bad it is, we remove the front post, the front post and bracing, or the entire bottom.
We set the repair kit in place, lower the upright onto it, and bolt it. Bolting it correctly matters. Done wrong, the connection puts too much stress directly on the bolts.
Each repair kit has a shelf the upright needs to sit on. The bolts hold it in position, but the weight of the upright should rest only on the repair kit. If the weight hangs on the bolts instead, a bolt can shear off and drop the upright onto the shelf. That is why the upright must sit on the shelf from the start.
We anchor the upright back to the floor and haul away any leftover scrap metal.
Usually, yes. That is where most of the time savings come from. Lighter product that is properly secured can stay on the rack while the kit goes in. Heavy or overhanging loads are the exception. We will ask you to unload those racks before we lift the upright.
Replacement is better when an upright is damaged heavily front and back. It is also better when the damage is spread across many places and heights, so no single kit covers it. And when uprights are short and standard, new material is usually cheaper than the labor to repair the old. One more case: if you are relocating soon, do not repair rack you are about to tear down. Our reps can run the numbers both ways during the on-site survey.
Forklift impact is the leading cause. Improperly loaded racks also take a toll. That means loads too heavy for the frame and beam capacities, or loads spread unevenly. Harsh environments like freezer, outdoor, or wet storage cause damage too. The cheapest ways to prevent the next hit are column protectors, clear aisles, visible load-rating signs, and certified forklift operators.
At least once a year, and more often is better. Also inspect right away after any collision or visible damage. Check that racks are level and plumb. Check that uprights are straight; a straightedge held against the column will show gaps at weak points. Check that beams are not bowed or sagging, that clips and hardware are all present, and that anchors are tight.
Sometimes. Stein is a licensed general contractor in both North and South Carolina. If your repair or replacement needs a permit, we handle the paperwork as part of the job.
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If you have damaged pallet rack you need to have repaired, we can help get your business back on track — contact us today!
