When damage to an industrial steel pallet rack system column or frame has been discovered, RMI’s publication “Guideline for the Assessment and Repair or Replacement of Damaged Rack – Version 2” suggests multiple options for repairing the damage. Among the repair choices available to rack owners and operators are to work with the original rack equipment manufacturer (OEM) to obtain a bolted upright frame repair kit, or to perform a welded field repair.

Repair kits, developed and offered by most RMI member companies, allow removal of damaged sections of rack for replacement with a like-new product that is bolted in place. By working with the original rack manufacturer and a qualified engineer, the rack owner can be confident that the repair work will be fully compatible with the current system and continue to create a safe working environment.

Bolted Repair Eliminates Welding Risks

A bolted repair can eliminate the risks and complexities associated with a welded repair, which may seem to be the fastest and most economical approach to correcting the damage. In instances where OEM-provided replacement or repair kits are not an option, field welding may be the only available solution — short of replacing the system. Field welding performed by an on-site maintenance technician can be a risky repair technique that may result in an unsafe rack system if the work is not completed correctly or without adhering to several safety practices in order to mitigate those risks.

Field Welding Risks

As outlined in Annex A of RMI’s publication “Guideline for the Assessment and Repair or Replacement of Damaged Rack – Version 2” field welding risks include:

Risk # 1: Fire

Because welding throws sparks into the surrounding area, they could ignite a fire that results in catastrophic building and product damage, particularly if flammable materials are located nearby. Prior to making any repair to damaged racking, an operation should engage a qualified, professional engineer. The engineer will supervise and direct the assessment, design, and installation of the remediation process. Should the engineer determine that field welding is the only way to ensure the repaired section is in alignment with the RMI’s ANSI MH16.1: Specification for the Design, Testing and Utilization of Industrial Steel Storage Racks, the welder must comply with all recommended fire and safety procedures, including those outlined by OSHA standard 29 CFR 1910.252(a).

Risk # 2: Weld Contamination

All welding performed during a rack’s manufacture occurs in a controlled environment prior to painting. This ensures the resulting welds meet engineered design requirements. Per the American Welding Society Specification – D1.1/D1.1M [3]; Section 8.5.1 Base-Metal Condition, surfaces must be completely clean prior to welding. Before welding occurs, the repair team should remove any paint on the rack component’s surface to expose bare metal. It can be difficult to properly and thoroughly clean a welded joint in the field. That increases the risk of a contaminated and weakened weld, that may fail when the repaired rack structure returns to service.

Risk # 3: Operating Temperature

The success and strength of a weld is dependent on environmental conditions. Before allowing field welding, give special consideration to the environment. Cold or frozen environments, for example, require special low-temperature welding techniques to ensure a safe repair.

Risk # 4: Welder Certification

A welder’s certification is site specific, rather than universal. Chances are, this certification likely does not apply to the types of welds needed for a specific repair. That is, in order to earn a certification in a specific welding technique, the welder must first complete specialized training to perform that type of weld. They must then demonstrate those unique skills to earn the associated designation. Therefore, do not assume that a field welder can produce the type of weld required for a safe rack repair. The supervising repair engineer should first review and approve the individual’s welding certification documentation prior to allowing him or her to perform the work.

Learn More About Rack Repair

Download RMI’s Guideline for the Assessment and Repair or Replacement of Damaged Rack – Version 2.