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Racking is the universal storage solution for warehousing and logistics applications. However, the specification of the racking is critical, as is the maintenance and inspection regimes.

Unfortunately, these are often overlooked when a purchasing decision made, and therefore companies are opening themselves up to unnecessary and avoidable risks.

Below are some basic notes on racking and what to look for, along with our own twelve commandments for safety in storage locations. Feel free to download these as you wish.

Structural Strength

Pallet racking started life as sheet metal, which is formed into the shape you observe. They are designed to take vertical loadings, and have very impressive compression characteristics.

However, introduction of a sideways compression and things can go disastrously wrong. A small kink of 3mm over 1m or less is hard to notice with the visible eye, yet can de-rate the rack by up to 75%. It also affects anything to which it happens to be fastened.

Adding to this complication is the fact that steel is silent, with no warning of impending collapse or yielding. In comparison, miners always preferred wooden pit props, which gave a little warning of impending trouble.

Visible strikes are worse still in the effect on load ratings, and fork lift impact needs to be taken extremely seriously.

To provide some indicators, we have compiled some notes on looking after racking:

1. Avoid all contact with mechanical handling equipment.

2. Make sure floor fixings are tight – they account for up to 20% of the structural strength of the rack.

3. Inspect daily and in depth at least once a quarter (more frequently if new operatives introduced). Tell all operatives to report damage, however slight.

4. Ensure pallets are the right size for the rack and placed correctly on them, within the load capacity zones. Ensure load is distributed evenly.

5. The Banana Effect: Beams that don’t return to the horizontal when unloaded have been subjected to excess loadings and are now out of specification. Our professional advice is do not use such beams.

6. If damage is observed, then the bay should be unloaded. Weakness in the structure is easily transmitted through connected bays.

7. A simple rule of safety: If you would not be happy for your family to be in the environment, then it isn’t safe for anyone else to be there.

Ensure your racks are clearly marked with loading details and that colleagues are correctly and regularly instructed in your warehouse procedures.