Warehouse Safety
Our warehouse safety work starts with the rack. We inspect pallet rack, rank the damage by severity, and install rack protection.
Certified byRoss UllmanPresident, Stein Service & Supply
Warehouse Safety Services
We provide rack inspections, rack protection, safety programs, and safety training for warehouses. We rank each item of rack damage by severity, so the most serious damage is repaired first.
Our home region is North Carolina, South Carolina, Georgia, and Virginia. In 2025 we also completed projects in 24 other states.
- Rack inspections and surveys of damaged uprights
- Damage ranking from Low to Unload, with repair or replacement for each upright
- Column protectors, end-of-rack guards, guardrail, and safety netting
- Hazard assessments and written safety plans
- Forklift, lift, and rack safety training for staff
- Guidance on fire code housekeeping requirements
Fire Code Housekeeping Requirements
New rack requires a permit and an inspection, and the fire code continues to apply after the rack passes that inspection. Chapter 32 of the fire code includes housekeeping requirements for rack storage, and the fire marshal checks them at the annual fire inspection. The examples below are from North and South Carolina, which number the sections differently.
| Requirement | Application in the Warehouse | Code Section |
|---|---|---|
| Damaged rack | Rack must remain structurally sound. A bent upright or a dislodged beam is a fire code violation and a safety hazard. | 3205.1 NC, 3205.2 SC |
| Open aisles | Aisles must stay clear to the required width during loading, unloading, and restocking, so that people can exit. The minimum width is typically 44 inches, or 96 inches where forklifts place the storage. | 3205.4 |
| Permitted layout | In South Carolina, the code requires the permitted layout to be verified each year, and the layout cannot change without prior approval. | 3205.1 SC |
| Storage height line | The fire marshal can require a line on the wall, such as a painted yellow line, that marks the maximum storage height. | 3205.6 NC, 3205.7 SC |
The fire marshal inspects operating warehouses every year. Many owners learn at that inspection that a change they made to their storage required a permit they did not obtain.
Rack Inspection Schedule
Forklifts cause most rack damage, and drivers rarely report an impact. Because a small dent near the floor can reduce the capacity of an upright, we recommend three inspection schedules and an immediate inspection after any reported impact.
Walkthrough
Weekly
Daily in shipping and loading areas
A trained employee inspects the aisles for unreported dents, loose beams, and pallets in contact with braces.
Scheduled Inspection
Quarterly
By trained staff, or as often as monthly
Every inspection is recorded. Beams and bays often change after installation, and the record shows who made each change and when.
Expert Inspection
Yearly
By an outside professional
Establishes a baseline for comparison each year and confirms that the loads and lift trucks still match the rack.
Signs of Rack Damage
Most damage occurs on the front post of the upright, at forklift height, and it ranges from a dent to a post that is detached from the floor. We rank each finding as Low, Medium, High, or Unload. Repairs use like-for-like parts or an engineered repair. Pallet rack repair
- Bent, dented, or twisted uprights
- Bent or cracked beams
- Missing beam safety clips
- Loose or corroded anchors
- Crushed column protectors
- Rack that is out of level
- Loads above the rated capacity
- Rust or corrosion
Rack Protection
Guards absorb impacts before they reach the rack, and they cost less than replacing the uprights they protect. Guardrails and rack guards
Ends of Rows
End-of-rack guards protect the corner uprights where forklifts turn. The code does not require them, but some inspectors require them before they approve a new installation.
Uprights in Heavy Traffic
Column protectors are installed at the base of the upright, where a forklift impact is most likely.
Walkways
Guardrail separates pedestrians from forklift aisles. A single row of rack with a walkway behind it requires safety netting to catch product that a forklift pushes off the back.
Installation Site Safety
Safety also applies to our own crews when they work in a customer’s building. Our crews follow the safety rules of each site. For a global mineral company, every installer completed 24 hours of site-specific safety training and attended the required on-site safety briefings. Read the case study
On every project, we work to ensure that each installer, whether an employee or a subcontractor, is licensed, insured, and trained on forklifts and scissor lifts. Our crews have the steel-toe boots, vests, hard hats, gloves, and other equipment that each site requires. The requirements are different for each customer.
Safety Programs and Training
For the customer’s staff, a safety program starts with an assessment of the building, followed by a written plan and training.
Hazard Assessment
We match the assessment to the building and its operation, because a single-shift storage building requires a different review than a 24-hour distribution center. Corrective actions start with removal of the hazard, then guards and barriers, work rules, and personal protective equipment.
Written Safety Plan
The plan records operating procedures and training, so that every shift completes the work the same way, and it identifies hazardous areas and labels hazardous materials. It also covers fire extinguishers and a posted exit plan.
Employee Training
Forklift operators must be trained and certified. We also train staff on rack safety, so that they can identify and report damage.
Forklift training Boom & scissor lift trainingWarehouse Safety Questions
What should be done after a forklift hits an upright?
Do impact sensors replace rack inspections?
What does OSHA require for rack inspections?
What are the most common warehouse safety violations?
Do changes to existing rack require a permit?
What do inspectors check on a new rack installation?
Contact
Discuss a Warehouse Safety Project
Contact us with a description of the rack damage or the date of the upcoming inspection.