Pallet Racking Inspection & Damage

Pallet racks hold tons of product over the heads of workers. A forklift bump that bends an upright can reduce its strength dramatically, and one failed upright can bring down a whole run of racks in a chain reaction.

• Warehouses
• Distribution centers
• Forklift operators

Signs of damage

• Bent, dented, twisted or creased uprights (columns), especially near the floor
• Bent or sagging beams, or beams with cracked welds
• Missing beam locks (safety clips or pins)
• Missing, loose or broken floor anchors and baseplates
• Damaged bracing between uprights
• Racks leaning or out of plumb
• Missing or damaged wire decking and pallet supports
• Pallets overhanging, broken or not seated on both beams

Capacity

• Racks should have load capacity plaques showing the maximum load per level and per bay.
• Don’t exceed the rating, and don’t move beams up or down without checking that capacity still applies; changing beam spacing can lower capacity.
• Place heavier loads on lower levels when possible.

When a rack is hit

1. Report it right away, even if the damage looks small. Hiding a rack hit puts everyone at risk.
2. Unload the affected bays and tag them out of service.
3. Have a qualified person assess the damage using the rack maker’s or industry guidance.
4. Repair or replace with the maker’s parts or an engineered repair kit. Don’t straighten or weld uprights in place.

Prevention

• Column guards and end-of-aisle guards at high-traffic corners
• Clear aisle widths for the trucks in use
• Trained operators who slow down near racks
• Regular inspections: daily walk-throughs by staff, and periodic formal inspections by a qualified person
• Keep flue spaces open between back-to-back loads so sprinklers work

Last updated: October 2, 2026