Pallet racking is a vital commercial environment storage solution meant to store pallets safely, allowing easy access to the items kept on the racking while maximizing the use of limited space. However, working around pallet racking systems comes with several hazards, risking employee and product safety.
Unsafe pallet racks can cause crushing injuries due to falling items or instability/ collapse of the racking system. They can also result in pallet racking failure. Outlined below are four common pallet racking safety hazards.
1.  Rack overloading
The quest to maximize storage space can result in pallet system overload, posing major safety threats. Overloading your racks can lead to:
- Higher accident and injury risks
- The racking system’s structural damage
- Lower lifespan of your racking system
- Safety regulation non-compliance
- Death risks
- Inventory damage
Pallet racks are designed for particular load capacities and weight limits. It’s important to learn how to calculate the load capacity of racks before storing anything on them to ensure warehouse safety. If you have limited space or require more room during peak seasons, don’t be tempted to overload your racking system because doing so can compromise staff, equipment, and stock safety.
2.  Poor pallet rack installation
An improperly installed pallet racking system can result in disastrous outcomes that impact a warehouse’s productivity, efficiency, and daily operations. Also, they increase workplace injury risks. Pallet racks set up using unbalanced shelving levels, loose bolts, or a malfunctioning VRC (vertical reciprocating conveyor) can collapse easily, endangering your warehouse assets and putting your staff in danger of falling debris. This can lead to high:
- Worker’s compensation premiums
- Legal and insurance fees
- Lost revenue, especially when damaged inventory can’t be sold
Seeking professional rack installation services can help lower the safety concerns associated with improperly installed pallet racking systems. The right pallet rack installer should be duly licensed and have several years of experience doing rack installation work.
3.  Ignoring pallet rack repairs and preventive maintenance
Overlooking pallet rack preventive maintenance and repairs significantly contribute to warehouse safety risks. Daily wear and tear can compromise the structural integrity of your pallet racking system. Creating and keeping up with a routine maintenance schedule can help enhance workers’ and stock safety while guaranteeing smooth warehouse operations. Additionally, completing repairs as soon as you notice them can help heighten warehouse safety. Preventive maintenance helps minimize long-term warehouse expenses by:
- Lowering employee injury risks that can result in high worker’s compensation
- Preventing inventory and equipment damage
- Avoiding major, costly repairs down the line
4.  Damaged pallet rack
Damaged pallet racks are a significant threat to warehouse safety. While pallet rack damage (broken, twisted, or bent components) is hard to miss, some damage isn’t easy to spot, increasing the potential for catastrophic accidents. Looking out for the following rack damage warning signs and addressing them promptly can help prevent the risk of accidents and injuries:
- Loose components
- Bent or buckled uprights
- Poor alignment
- Bent braces
- Beam deflection
- Missing beam safety clips
- Rust and more
Regular pallet rack safety inspections allow you to spot these issues early enough and resolve them before they can escalate and cause severe safety issues. Fixing pallet rack damage promptly also saves money because when damage is ignored for an extended period, it becomes a big issue that costs more to address.
Endnote
Pallet racking safety is vital to ascertaining operational efficiency and your staff’s health. Familiarize yourself with the common pallet safety hazards to ensure a safe working environment.
