How to Properly Repair Pallet Racking Systems

Table of Contents

• Understanding Warehouse Racking Systems
• Identifying Issues with Warehouse Racking Systems
• Repairing a Damaged Warehouse Racking System
• Custom Warehouse Wire Decking

Warehouses depend on sturdy, reliable pallet racking systems to run smoothly. Since pallet racking systems are vital to everyday warehouse operations, they are bound to withstand the occasional knock. Racking systems can also become damaged from lack of maintenance, environmental factors like rust, impact from forklifts, and overloading racks or other improper storage techniques. It is important never to ignore a damaged pallet racking system, as this can affect the safety and efficiency of your warehouse’s operations. 

That said, replacing an entire system can be a lengthy and costly process. Hiring a quality pallet-racking repair service offers an efficient and reliable solution. This blog explores how to repair pallet racking systems, but hiring a professional service is the way to go to reduce downtime and make your shelving compliant, safer and more reliable.

Understanding Warehouse Racking Systems

Before diving into repairs, it is essential to understand pallet racking systems. There are various types with various components, and understanding the differences is key to reliable pallet rack repairs.

Types of Warehouse Racking Systems

Depending on your warehouse, you could have one specific type of pallet racking system or a mix of various pallet racks. Types of pallet racking systems include: 

• Selective: This popular system is also called static racking. It allows you to store loads at different heights with full and easy access. 
• Push-back: This is a last-in, first-out (LIFO) system that pushes previous pallets to the back when new pallets are loaded. The system uses a trolley or roller to displace pallets. 
• Drive-in and drive-through: These high-density systems optimize space by eliminating work aisles. It offers a single entry and exit for forklifts. 
• Pallet flow rack: This system is also called gravity flow rack and is an example of the first-in, first-out (FIFO) method. 
• Cantilever: Cantilever racks have arms connected to the upright posts so that it is possible to store long items like carpets and pipes. 

Racking Components

Warehouse racking systems components include:

• Uprights: These frames are vertical columns with bracing that run from the floor, where they are bolted in, to the top self. Uprights connect and support the beams. 
• Beams: The beams are the horizontal bars attached to the uprights. The beams support the weight of pallets, and different beams have different load capacities. 
• Pallet supports: Several pallet support bars run across beams to support smaller items. With pallet support bars, you can also fit shelves into your racking system. 
• Wire decking: Like pallet support bars, wire decking provides extra support across beams, but it is also more versatile than support bars, which are meant to support pallets only. With wire decking, you can store containers. 
• Base plates: Base plates, or footplates, are vital components for securing uprights when they are bolted to the floor. Other essential components for securing your system include anchors, bolts and shims that help level uneven surfaces. 
• Accessories: Organizational and product protection accessories like column guards protect uprights from damage from forklifts and help optimize storage.

Identifying Issues With Warehouse Racking Systems

Pallet racking systems can become damaged due to:

• Forklift collisions: One of the leading causes of pallet racking damage is forklift collisions. Impacts can damage uprights, beams, supports and other important structures. Collisions can happen because you have the incorrect type of pallet racking system for your warehouse’s layout or have not optimized systems for your layout. It may also happen because of insufficient operator training or poor lighting. 
• Overloading: Another common cause of pallet racking damage is overloading the system. Beams have different load capacities. Going over that capacity can cause beam deflection — excessive bowing or sagging — compromising the system’s integrity and posing a significant safety hazard for staff.
• Poor installation: A poorly installed system that is not structurally sound could collapse and cause injuries or fatalities. Always have a professional team install racks so that they are reliable and meet industry standards.
• Environmental factors: Depending on what your pallet racking is made of, exposure to the elements — like moisture from humidity — can weaken it over time. A wooden system can become waterlogged, and a steel system may rust. 

Common Signs of Damage

Regular safety and maintenance checks are a standard that helps keep the work area safe. When inspecting your pallet racking systems, look for these signs of damage: 

• Beam deflect: Are your beams sagging or bowing under the weight of a load? Damaged beams may tilt toward one another. If beams are damaged, they won’t support the weight of a load anymore, which is a structural concern and a safety hazard. 
• Damaged uprights: You want your uprights to be robust. To do so, determine how “plumb” or “straight” uprights are. An out-of-plumb upright refers to a bent column, while an out-of-straight upright causes excessive sagging or bowing. 
• Loose connections: Beam connectors join beams to uprights. If using a bolting system, check the connections for bends, cracks or missing pieces. Bolts should not be loose or missing.
• Cracked, warped or unlevel floors and feet: Check the floors for damage like cracks and unevenness that can compromise the stability of your racking system. Check the rack’s feet to ensure there is no warping, bending or cracking and that they are level and secure.

The Risks of Damaged Pallet Racking 

Leaving damaged racking systems unchecked is a recipe for disaster. If the rack collapses, warehouse staff can suffer serious injuries, or the collapse may result in fatalities. Inventory can also become damaged or completely destroyed. In both scenarios, the costs of compensating for injury, death and loss can cost hundreds or even thousands. 

Repairing a Damaged Warehouse Racking System

It may be possible to repair your systems if the extent of the damage isn’t severe. Having an expert check and repair your racking systems is always the right and best call if the damage is extensive. 

You may follow these steps for minor fixes: 

1. Assess the damage, and get all the replacement parts and tools you need before starting repairs. 
2. Always clear the area that needs repair. No unnecessary staff should be working or stopping by the area where repairs are underway. 
3. The area that needs repairing should be clean and free of clutter. 
4. Anyone working on repairs should wear the appropriate personal protective equipment (PPE). 
5. Empty the rack of all stored items.
6. Disassemble the damaged sections carefully. 
7. Replace or repair damaged parts. 
8. Reassemble the rack, being extra careful to follow manufacturer instructions. 
9. Ensure the parts are secured and that the reassembled section is aligned and level.
10. Load the rack safely, slowly and within the appropriate capacity to check that the weight is evenly distributed and that the repair is sound.

Preventing Future Damage

To prevent your rack from becoming damaged, be sure to conduct routine maintenance and safety. Training staff and keeping them updated with the latest safety standards and procedures helps keep them safe as well as protect the racking system. 

Custom Warehouse Wire Decking Solutions From Tennessee Rack

Storage systems are part of a warehouse’s foundation. A damaged system is never worth the risk. With a trustworthy racking system, you add to the excellence and reliability of your warehouse. Quality racking systems optimize your storage, improve efficiency and boost overall safety. 

At Tennessee Rack, we offer custom storage solutions by designing and installing rack storage systems that suit your warehouse’s needs. You can rely on us for quality products and services. We also fulfill most orders within 48 hours. Contact us at 615-722-4281 to speak to our helpful consultants about your ideal warehouse storage solutions — whether you need rack installation services near you or an entirely new system due to damage. You can also send through an online form to request a free quote.