Pallet racking systems are essential components of modern warehousing and distribution centres, providing efficient storage solutions for a wide range of goods. 

However, improper handling and maintenance of these systems can lead to safety hazards, reduced efficiency, and costly repairs. 

Let’s explore some of the most common pallet racking mistakes and provide valuable tips on how to avoid them, ensuring a safe and optimised storage environment.

Mistake 1: Overloading the Racks

One of the biggest mistakes is overloading pallet racking systems beyond their designed load capacities. Exceeding weight limits can strain the structure, leading to damage and, in severe cases, structural failure. To avoid this mistake, follow these steps:

• Clearly label load capacities on each rack and educate all warehouse staff on their importance
• Regularly inspect loads to ensure they comply with weight limits
• Invest in load-bearing beams that can handle the intended weight

Mistake 2: Ignoring Regular Pallet Racking Inspections

Neglecting routine inspections is a grave mistake that can lead to undetected damage or wear. Inspections should be carried out regularly to identify issues early on and prevent potential accidents. Avoid this mistake by:

• Scheduling regular inspections by a SEMA approved racking inspector
• Training warehouse staff to recognise and report any signs of damage or irregularities
• Addressing identified issues promptly with appropriate repairs or replacements

Mistake 3: Improper Loading and Unloading

Incorrect loading and unloading practices can damage the racks and pose safety risks to employees. Avoid this mistake by:

• Providing proper training to staff on safe loading and unloading procedures
• Using the correct material handling equipment suitable for the racks and loads
• Avoiding sharp or rough handling that may cause damage to the racking system

Mistake 4: Neglecting Pallet Racking Safety Measures

Failing to implement and enforce safety measures is a serious mistake that can lead to accidents and injuries. To ensure a safe working environment, take these steps:

• Clearly mark designated walkways and keep them free from obstructions
• Use appropriate safety equipment, such as safety nets, column guards, and rack protectors
• Conduct regular safety training for all employees and enforce safety protocols consistently

Mistake 5: Incorrect Installation and Configuration

Improper installation and configuration of pallet racking can compromise the stability and integrity of the entire system. Avoid this mistake by:

• Having the racking system installed by experienced professionals following the manufacturer’s guidelines
• Double-checking all measurements and ensuring that the racks are level and properly secured
• Avoiding unauthorised modifications to the racking system

Mistake 6: Lack of Proper Maintenance

Failing to maintain pallet racking regularly can lead to gradual wear and tear, reducing the system’s lifespan and efficiency. Prevent this mistake by:

• Implementing a regular maintenance schedule, including cleaning, lubricating, and inspecting components
• Keeping accurate records of maintenance activities and repairs
• Consulting with the manufacturer or a qualified engineer for any major repairs or modifications

Avoiding common pallet racking mistakes is crucial to maintaining a safe, efficient, and productive warehouse environment. 

We serve the whole of the UK with new pallet racking and second hand pallet racking and offer nationwide delivery. Therefore, if you are interested in purchasing racking for your business, contact us FREE today for a quote.

Give us a call on 0800 345 7088 to discuss your storage needs, or email [email protected]. 

With us, support continues after the sale, and we strive to form strong customer relationships, providing you with dedicated advisors you can contact for any advice.