In a perfect world, there would be no warehouse accidents. People, product and pallet rack would all be free from any threat of collisions, collapses and the lingering threat of unavoidable freak accidents. Unfortunately, we live in the real world, and although we’re edging our way closer to perfect, we’re not there yet. It’s likely over the course of time that at least one warehouse mishap will take place. Many of these accidents occur while a forklift operator is loading or unloading product in or out of a pallet rack system. The picture below shows an extremely common sight in warehouse sight: a frame that’s been dented as a result of a forklift collision. The severity of an incident such as this can vary depending on the load being supported by the frame and several other factors, but it’s clear that some action would need to be taken after the initial accident. But how do you know if you need to replace the damaged racking? You could try assessing the damage and basing your decision on a hunch, but a better way to figure out how to know if your racking needs to be replaced is to reference the Rack Manufacturers Institute standards.

Should Damaged Pallet Rack Frames and Beams be Replaced?

How to Know if Your Racking Needs to be Replaced
Adding column protectors or end-of-aisle rack protectors defends both damaged and healthy columns alike from forklift impacts, lessening the likelihood you’ll need to replace them in the future.

Before we jump to talking about whether or not you should replace a pallet rack component, we want to touch on what to do in the unfortunate case that an accident does take place. The Rack Manufacturers Institute (RMI) Specification says that “Upon any visible damage, the pertinent portions of the rack shall be unloaded immediately by the user…” This first part is the key to maintaining safety in the warehouse because even if the racking appears unwavering after the initial impact, it may be left structurally unsound and could be unsafe to operate around.

Once the racking has been unloaded, RMI states that “the damaged portion shall be adequately repaired or replaced.”  Of course, the viability of the component should be determined by someone with the proper knowledge of pallet rack engineering. It’s also important to note that using a repair kit instead of replacing an upright frame automatically voids the product warranty for many rack manufacturers. With this in mind, more often than not it’s a good idea to replace the component. As far as costs are concerned, replacing a frame is often equal or lesser cost in the long run and is more likely to yield a safer setup.

RMI further states if the damage were to re-occur, the application of the racks should be reviewed to see if modifications could be made to lessen the severity or the frequency of the damage. In other words, the best way to handle a warehouse racking accident is to prevent it from happening in the first place. As always, forklift driver training is essential.

Have other questions about pallet rack safety and whether or not you should repair or replace your racking? Give us a call at 888-578-1579 and we’ll be happy to help!

Source: RMI