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Avoiding Warehouse Catastrophe: A Guide to Secure Storage Rack Systems

With warehouse and shipping logistics becoming a billion-dollar industry, there’s more of a need than ever to have warehouse space that’s properly designed. A warehouse and its storage rack systems ensure that products are safe and secure and ready when you need them. If warehouse rack systems are poorly installed, it could lead to major issues in the long run.

Here are a few things you can do to secure your warehouse racking system.

Protect From Collision Damage

Using the right storage rack system means finding one that is durable and can withstand the wear and tear put on it in a warehouse. It will have to bear all kinds of weight, all kinds of substances, and on top of everything, be able to handle the physical damage of a forklift collision.

If a collision occurs, the damage could be far worse than just the damaged forklift. The entire structural integrity of the racking system could be compromised. This could significantly damage the frame, requiring immediate replacement and repair.

Your workers, staff and even part-time lumpers need to be trained to monitor and report the damage to racking systems as soon as it occurs. Even minor impacts should be reported officially. This ensures that no small issue turns into a major one over time.

Reporting damage to any load-bearing columns keeps the collision from turning into a complete collapse. This is a far more dangerous situation than the forklift collision, so if that was an issue, you certainly want to avoid a collapsed racking system.

Make sure you have all of the right systems in place to protect your warehouse from a collapse. You’ll need rack bollards, drive-in floor channels, and frame-ed guards. These keep the damage down to a minimum.

Also, look at the specifications of your handling equipment when you install your racks. This keeps enough clearance space so you can easily maneuver your manual equipment around.

Racking is not the only asset that should be protected from a collision. Warehouse docks should be kept clear of debris. Trucks operating around warehouse docks should use sonar or camera backup safety systems to avoid damaging docks.

Avoid Improper Use

Using your racking system in a way other than what it was designed to do is dangerous. It could pose a serious safety hazard and end up in injury.

In order to preserve your system and to prevent injury, you need your staff to be trained to operate your equipment. Otherwise, they risk harming themselves or others during their workday. The weight limits should be abided by carefully so that your staff doesn’t put their coworkers in harm’s way.

Overloading a rack can also damage your rack. It’s one of the main ways that racks become damage and leads to problems in pallet racking. To keep people from overloading, listen to what the manufacturer has said.

Your weight limits should be clearly displayed for staff to see. While you can’t force everyone to adhere to them, enough reminders and proper training can be encouraged. Give a regular assessment and run audits to ensure that the weight is properly dealt with.

Workers should be trained to place their loads evenly for better distribution. The maximum weight capacity should be checked before anything new is added to a rack.

Watch Overhanging Products

Another major hazard in warehouses is overhanging products. While weight is normally distributed to that this isn’t an issue, it can become one even with a few cut corners. Overhanding products stored on a rack that’s only designed for the pallet itself can lead to product damage.

It’s a safety hazard when the length of the overhanging product surpasses how deep the shelf is. This happens a lot in warehouses that use previously owned pallet racking systems. Those racks aren’t usually designed for the products that they store.

Getting a custom pallet racking system is a good way to ensure that the racks you use are designed to store the products that you use. This allows the racking manufacturer to consider any product overhang.


Overhang could lead to damaged equipment that gets dinged up and scratched. It also leads to a potentially damaged product. This could hurt your bottom line.

In the worst cases, a pallet could tip and fall due to the weight. The rack itself could even be pulled down in some extreme cases. The domino effect of this could be too extreme to risk it, so make sure that you’ve got racks designed for your products.

Install Your Racking Correctly

Racking that’s not properly installed could lead to serious hazards. If pallet racking isn’t installed correctly, it’s a health and safety issues. Things falling, tipping, or leaning often result in unintended consequences.

You can avoid this issue by simply having your racking installed by properly trained pallet racking specialists.

When they’re installed, check that everything is properly aligned. Don’t be afraid to break out a level and make sure that everything is properly balanced. You want all surfaces flush so that you’re better prepared for the day to day use that you need your racking system for.

If you’re not sure about whether or not your racking is installed correctly, you should consider booking an inspection and a safety audit. It’s much better for your staff and your warehouse to have everything checked out rather than leaving it up to question.

Storage Rack Systems Are Vital to Operations

Your storage rack systems are the skeleton framing your entire warehouse operation. If they’re properly designed and suited to your needs, you can ensure that your warehouse operates safely and smoothly. When your racks are secure, so is your profit margin.