Committing to regular, routine inspections of industrial steel storage racking is a key measure toward ensuring the safety and performance of a rack structure. To help owners and facility operators perform a rack inspection, RMI’s ProMat 2019 presentation, “Storage Rack Safety 101,” includes a checklist of areas to examine.

What to Examine During a Rack Inspection

First, it’s important to review the manufacturer’s load application and rack configuration (LARC) drawings and installation guidelines, and compare that information to the existing rack structure. Potential issues might include unauthorized beam height elevation changes that do not match the original LARC, or other modifications that do not correspond to the rack manufacturer’s design and could pose a safety risk.

The different components that should be looked include (but are not limited to):

1. Condition of stored pallets and loads.

Determine if loads have been placed properly on the pallets, and that the pallets placed properly on the beams. In areas with a higher risk of seismic activity, it may be necessary to restrain or contain the product on the pallets as an additional precaution. Also, look for uniform load distribution to ensure the maximum load weight has not been exceeded.

2. Rack anchorage.

Verify that the correct number and location of anchors are in each base plate (both aisle and rear column) and evaluate the condition of the anchors themselves. Ensure that anchors are intact (not broken off or pulled out of the floor) and that the nuts on the anchor bolts are snug-tight.

3. Column base plates.

Inspect the joint where the column upright is welded to the base plate to ensure the two are attached securely.

4. Columns.

Determine if any columns show distortion or bending from impacts. These occur most frequently to columns facing the aisle or at the end of a row or a tunnel, where forklift collisions are more likely. If in place, check the condition of free-standing or directly attached column guarding to confirm its reliability.

5. Frame bracing.

Inspect any horizontal or diagonal bracing used within the rack uprights for damage from impacts.

6. Shelf beams and connections.

Verify that beams are seated, and that beam connection locking devices are in place and secured properly. Look for excessive deflection due to overloading or point loads as opposed to uniformly distributed loads. Make sure the shelf beams are straight and not bent from cross-aisle handling equipment impacts. These are particularly likely to occur at the lowest level but may also happen at upper levels.

7. Wire decks.

Confirm that any decking structures are intact, with no damage to reinforcement channels or wire mesh. Also verify  that each piece of decking is firmly seated in place.

8. Pallet safety bars.

Determine whether all barriers and netting—installed to prevent products from falling to the ground from their elevated storage position—are in their proper place and securely fastened to the frame and/or shelf beams.

9. Accessories.

Evaluate any other accessories added to the rack, including protective devices.

What to Do After Completing a Rack Inspection

Should the inspection uncover any damage or other unsafe condition, unload the racking immediately for repairs. Perform repairs under the guidance of a qualified, professional rack engineer. This expert will assess the rack’s condition and oversee the ultimate repair or replacement.

Want to learn more about safe practices in industrial storage rack system installation, use and repair? RMI offers an extensive library of guidelines and standards publications available for download.