Pallet racking systems are a vital part of any warehouse storage system, providing efficient space management and ease of access to stored goods. However, overloading racking systems is one of the most common pallet racking mistakes — and it’s not a mistake you want to make at your facility. Not only can pallet racking collapse lead to significant equipment damage, but it can also cause injuries to nearby workers, thousands of dollars of damage to inventory, and other serious consequences. To ensure the safety of your warehouse, it’s essential to understand how to prevent overloading and protect the structural integrity of your pallet racks.
Here, we’ll discuss safety measures you can take to avoid overloading your pallet racking system and maintain the safety of your staff and equipment. By following these guidelines, you can create a solution for your warehouse that helps ensure safety and efficiency.
Understand the Load Capacity of Your Pallet Racking System
The first step in preventing pallet rack overloading is to understand the specific weight limits of your pallet racks. Each pallet racking system has a designated load capacity, and following these limits is crucial. Overloading your racking system beyond its load capacity can quickly lead to damage or even total collapse, threatening the safety of warehouse staff and potentially damaging stored items.
When buying a pallet racking system, always check the load requirements and ensure the whole system can handle the heaviest pallets you intend to store. Pay attention to both the racking system’s load limits and its height-to-depth ratio (a number that indicates the stability of the racking system based on its height and the depth of the shelves). A proper height-to-depth ratio is crucial because it helps prevent overturning, which can happen when racking becomes top-heavy or unstable.
Teach & Practice Proper Loading Techniques
You can’t overload your racking system if your pallets are underweight, right? Actually, this couldn’t be further from the truth. Pallet racking damage has other culprits in addition to weight overloading. Improper loading techniques are a common cause of pallet rack damage, even when individual pallets are within weight limits. Issues like unevenly distributed weight, placing pallets too high or too far out from the rack’s center, or not aligning them properly can all compromise the structural integrity of the strongest pallet racking systems.
Training warehouse staff on proper loading techniques is essential to avoid these risks. Pallet racking should be unloaded safely every time, not just some of the time. Ensure that all warehouse workers — especially forklift drivers — understand how to distribute loads evenly across shelves, avoid stacking too high, and follow specific weight limits based on the racks they are using. When pallet loads are balanced correctly, the whole system is more stable, preventing accidents and costly damage.
When In Doubt, Split Up Pallets
If you’re unsure about the load capacity of your pallet racking system or the weight of a particular pallet, it’s always better to err on the side of caution. Instead of risking overloading your racking system, split up heavy loads into smaller, more manageable pallet loads. By splitting up the weight, you not only protect the structural integrity of the racks but you also make it easier for machine operators to maneuver in narrow aisles. Whether you’re working with new or used racking, properly distributing weight can greatly reduce the risk of accidents. Always remember that the safety of your warehouse is more important than squeezing in extra storage space.
If You See Something, Say Something
Along with performing routine pallet racking inspections and implementing common-sense warehouse labeling ideas, ensure everyone in your warehouse is always on the lookout for any potential signs of trouble with your pallet racking. While small-scale pallet rack damage may seem inconsequential, we recommend that warehouse owners remove and repair — or replace — any affected pallet racking equipment ASAP. Even small dents or scratches may indicate underlying issues with your racking, such as internal rust or structural damage. If you suspect that something is wrong, speak up!
Keep Your Warehouse Safe With Diversified Rack & Shelving!
At Diversified Rack & Shelving, we offer high-quality new and used racking solutions designed to maximize your storage space while ensuring the safety of your warehouse. Whether you’re changing the way your existing warehouse stores items or installing brand-new storage equipment, our expert pallet rack installers can guide you through selecting the perfect system for your needs. Don’t run the risk of making common pallet racking mistakes or ignoring damage that could lead to a collapse. Contact us today to discuss solutions that ensure safety, efficiency, and peace of mind!