Free Pallet Rack
System Inspection

Are the racks plumb and level?

This is an issue with rack systems that have been reconfigured, poorly installed, or installed in areas where there may be foundation settling. The floor may have been inadequate and the rack installed with shims, which can move and skew. Collisions and impacts may have a greater impact on racks that aren’t set level. If you see crooked racks, rows out of alignment, or vertical leaning, it’s a red flag.

Is the rack overloaded?

Overloading is a prime cause or rack failure and the catastrophic damages & injuries that can ensue, so it needs to be addressed. It is an easy mistake to make and it’s made far too often. Changing the load without checking capacities is a serious issue. Remember that beams have rated capacity per pair, and that uprights depend on beam spacing for their capacity ratings. Visit your rack supplier’s technical documentation to find those ratings for your pallet rack or have The Rack Boss check the rating for you.

Are Uprights Bent or Damaged?

Do they have paint scrapes that might indicate a forklift hit? Damage, no matter how minor in appearance, can reduce the upright capacity for a section of the rack.

• Check the horizontal braces for any bending, twisting, or other damage.
• Check the footplates — they properly lagged and securely attached to the floor?
• Are column protectors damaged? If they are, did the upright also take damage in the incident that damaged the protector.

Checking Your Load Beams: Deflection, Dents, and Connections

Like the upright, beams can suffer damage from impacts. They can also be knocked out of a securely fastened position or either overloaded or misloaded, leading to failure.

• Check for damages: are dented, twisted, dinged, or even scraped indicating worse damage. Replacing a beam is easier and cheaper than the alternative of a collapse.
• Check for deflection: Beams naturally deflect beneath a load, and a certain amount of deflection is acceptable. It should disappear when you unload the beams. If it doesn’t, you should replace the beams—they have been deformed by overloading or impacts. In any case, beams shouldn’t bow more than 1/180th of the total length of the beam (for a 96″ beam, that’s half an inch).
• Are the beams properly attached to the uprights? Are the beams seated tightly into uprights? Are there broken welds or other signs of damage?
• Are the clips, bolts, or safety pins loose, missing or damaged? Most racks use some kind of connector hardware aside from the teardrop or keyhole to ensure tight fit and safety. Some even utilize more than one of these methods. Make sure they are all securely fastened and undamaged.

Let The Rack Boss ensure that your facility is safe and that your rack is in no danger of failure.