Designed to withstand the constant stresses of pallet loads, industrial steel storage rack is extremely resilient. It weathers routine wear and tear from loading and unloading with ease. At some point, however, damage can occur. Causes could be forklift contact, overloading beyond the rated capacity, or external forces—such as seismic events. Upon discovering rack damage, there are several recommendations to help a rack owner restore both the system and operational safety. Here’s what to do next.

What Does Rack Damage Look Like?

The Rack Manufacturers Institute (RMI) covers rack damage in ANSI MH16.1-2023: Design, Testing, and Utilization of Industrial Steel Storage Racks, section 4.4. The organization advises, “Owners of industrial steel storage racks shall implement inspection, maintenance, and reporting procedures to identify any visible damage or other conditions that could affect the load capacity or structural performance of the industrial storage rack system.”

RMI does not, however, provide any specific definitions of “damage.” Therefore, the effect of rack damage (such as a dented or crumpled component) on the system’s structural integrity may—or may not—be apparent, noted Arlin Keck, Principal Engineer at RMI member Steel King Industries.

“First, it’s important to note that uprights typically get the most attention. However, other components—such as beams, rub rails, anchor bolts, and connections—can sustain damage as well,” he advised. “Also, some dents or bends in upright posts and bracing, beams, row spacers, or other components may not look significant. However, associates should alert management about any noticeable changes in a component’s original shape or positioning.”

In other situations, the extent of the rack damage makes it obvious that repairs are necessary, Keck added. “I have walked through warehouses with loaded double-face selective racking where the bottom of an aisle upright post is so damaged that the post is barely touching the floor. Yet the rack is still standing.”

In a case like that, the need for an upright repair or replacement is absolutely clear, he continued.

“The only thing holding up the damaged frame is the upright behind it and the row spacers tying the back-to-back rows together,” he explained. “If that were to happen to a single-face row of selective racking, the situation could easily be worse.”

Get an Expert Opinion

Whether rack damage appears minor or glaringly obvious, RMI recommends engaging a qualified rack engineer to assess the system. This professional can help to determine the extent and severity of the damage.

The engineer can be with the original rack manufacturer or supplier, or an independent professional, Keck said.

“Having engineering expertise ensures proper supervision and direction of the assessment, design, and installation of the ultimate repair or replacement,” he said. “The engineer will also certify that the repaired section aligns with ANSI MH16.1 for the safest system overall.”

Based on the engineer’s assessment, it may be determined that an engineered rack repair kit from the original rack manufacturer or qualified third party will resolve the issue. These kits enable reinforcement—or removal and replacement—of damaged components with properly designed and engineered product bolted into place.

Sometimes removing the damaged parts and replacing them with identical new parts is a more economical option. Many warehouse managers stock a few spare uprights and beams for replacement of damaged parts. Stocking them in-house eliminates waiting for the manufacturer’s lead time to produce. The cost per stored replacement component can also be more economical when ordering them as part of the original system purchase.

Upright Construction Used Can Affect Stability

The style of post used for the uprights—cold-formed or structural—is another factor to consider when assessing rack damage, continued Keck. He noted that the capacity of an upright is dependent on the cross-sectional area and shape of the upright posts.

“For example, for cold-formed posts approximately 40% of the total capacity is a result of the cross-sectional area and 60% is due to the cross-sectional shape. Conversely, for a structural post 60% of the total capacity is due to the area and 40% is due to the shape,” he explained. “Obviously, a dent to a cold-formed post is more detrimental to capacity than the same dent to a structural post.”

High-Risk Rack Damage Scenarios

There are certain situations where damage to rack components is more critical to structural integrity and stability. These situations require immediate attention:

Isolate Severely Damaged Rack Immediately

Upon discovering severe rack damage—or damage in the high-risk situations mentioned above—Keck cited ANSI MH16.1’s guidance for next steps:

ANSI MH16.1-2023Upon identification of such conditions, the owner shall immediately isolate the affected portions of the industrial storage rack system and initiate a mitigative response, such as repair or replacement of the affected portions of the rack system. Before allowing the storage rack system to be placed back into service, a registered design professional shall certify that the storage rack system and/or the repaired components have been restored to at least their original design capacity.

“In these examples, immediately unload the bays adjacent to the damaged frame. Then, tape off the area until the damaged upright is repaired or replaced,” he said.

Ultimately, safety should be the primary objective when dealing with rack damage, Keck concluded. “You certainly want to maintain a safe working environment,” he said. “Safe for people in a warehouse, safe for the products being stored, and safe for the racking system and building.”

Get Answers to More Rack Damage Questions

RMI’s Guideline for the Assessment and Repair or Replacement of Damaged Rack details steps for surveying rack damage. It also offers guidance for ongoing reporting of damage and repairs. Additionally, RMI offers multiple resources detailing both standards and best practices that enhance the safety of people and pallet rack. This includes a series of videos, presentations, publications, case studies, frequently asked questions. There’s also an MHI Cast podcast recording about rack safety.