Pallet racking systems are the backbone of many warehouses and industrial spaces, as they allow for efficient storage and streamlined logistics. However, despite their benefits, these towering structures can pose serious safety risks if not managed properly.
Whether you’re installing new units or working with used racking, understanding the dos and don’ts of warehouse safety is critical. This blog covers key procedures that help prevent accidents, reduce damage and ensure long-term performance of your racking and shelving systems.
The importance of racking safety
A racking system is only as safe as its setup and maintenance. Strong and seemingly indestructible as they may appear, racks can easily become unstable or dangerous if mishandled. Misuse or neglect of your warehouse’s pallet racking setups can lead to a higher risk of accidents, potential injury to staff and personnel and damage to valuable stock. Implementing consistent safety measures not only helps protect your team but also keeps your operation legally compliant and efficient.
Do not overload racking systems
Overloading is the leading cause of racking collapse. Every pallet rack has a defined load capacity for both shelves and bays. Exceeding these limits can cause beams to bow or fail completely. To avoid overloading:
- Display visible load signage on each racking bay.
- Train staff to distribute weight evenly across shelves.
- Reassess loads if product types or storage patterns change.
Even small deviations in weight distribution can make a big difference. Uneven loads place disproportionate stress on certain parts of the structure, slowly compromising its integrity over time.
Avoid working or walking underneath racking
It may seem like a shortcut to duck beneath a rack to retrieve something, but this habit can be incredibly dangerous – especially if the structure is already compromised. The space beneath any racking should be treated as a hazard zone, rather than a shortcut, even with the tallet racking configurations which maximise your warehouse’s vertical space such as cantilever and narrow aisle racking. Creating marked pedestrian pathways away from racking lines can be one of the most effective methods of limiting personnel injury during racking accidents.
Bolt racking to warehouse floor
You wouldn’t leave a freestanding ladder in the middle of a warehouse. The same principle applies to racking. Without floor anchors, even the sturdiest racks are vulnerable to shifting during loading/unloading, collapse due to vibration or impacts or instability from uneven surfaces.
This is particularly critical with shelving setups where lateral movement or repeated loading cycles can easily lead to instability if not securely fastened, like with drive-in racking, which will frequently come into contact with forklifts and other lifting machinery. Proper anchoring is not just a good idea, it’s an industry standard and an essential part of safe installation.
Use proper workload signage
Workload signage is more than just a visual guide – it’s a critical part of risk management. Regardless of the racking type you’re dealing with, your staff must be aware of their load-bearing capabilities. Clear signs should include:
- Maximum shelf load
- Maximum bay load
- Racking model and configuration
This information must be accurate and clearly visible. If signage becomes damaged, obscured or outdated, replace it immediately to avoid confusion and non-compliance.
Regular racking inspections
Racking and shelving systems are not ‘set and forget’ structures. Over time, they suffer wear and tear, forklift impacts, and shifting loads. It’s for this reason why regular racking inspections are your frontline defence against failure. A two-tier approach to racking inspections works best, which includes both weekly visual checks to catch obvious issues early, as well as annual inspections by a qualified professional who can assess structural integrity in detail against SEMA guidelines.
Issues such as bent beams or uprights, missing or loose bolts, rust or corrosion and leaning sections can be quickly detected with this approach, leading to quick action that can prevent costly incidents.
Never modify racking without professional assessment
It might be tempting to adjust beam heights or swap out parts of your shelving on the go, to fit new pallets. But even minor tweaks can drastically alter the load tolerance and stability of a system.
This applies across all racking systems. For example, adding extra arms to a cantilever rack or reconfiguring a push-back system may seem straightforward, but without recalculating load dynamics, could compromise the entire setup. So before making any changes, consult with a professional who understands the racking’s specifications and ensure only certified components designed for that racking model are used. Mixing brands or forcing parts to fit is a recipe for disaster, and customisation should never come at the cost of safety.
Train staff on pallet racking safety protocols
Even the best safety plans fall flat if your team isn’t aware of them. Training is essential – not just during onboarding but as a regular part of workplace culture. Make it routine to do the following to ensure clear communication and visual reminder upkeep which can dramatically reduce risk.
- Run periodic training sessions covering racking safety basics.
- Update staff on changes to layouts, signage or procedures.
- Supervise new and agency workers closely until they’re familiar with protocols.
Conclusion
Pallet racking systems are indispensable to modern warehouses, but without the right safety procedures they can turn from assets to liabilities in an instant. By focusing on key safety areas – load management, structural security, regular checks and proper training, you can ensure a safer, more productive workspace.
If you’re looking to buy or sell used pallet racking, or need help with inspection, installation or repair services, get in touch with Pallet Racking Systems. Our team of experts can help you maximise safety, extend system life and keep your operations running smoothly.