Inspection Tips for Checking Racking Systems

pallets Own a warehouse stock business? Does it have pallet racking systems? Pallet racking systems are specially designed to support the storage of pallets for a set period of time. These racking systems offer many advantages for any business; however, it’s important to remember that proper maintenance should be carried out with all racking systems. The following are some inspection tips you can use to check your racking system to make sure it’s safe after long periods of use.

Inspection Tips You Need to Know

Are Your Beams Overloaded?

When beams are overloaded, it will cause an abundance of deflection. To work out whether your beams are overloaded, simply check the connectors at the parallel beam where two beams connect at an upright. If your racking system is overloaded, it will cause deformities at the connectors with an evident V shape.
You may also see evidence of “permanent set” with unloaded beams. In cases such as this, the racking system will need to be inspected thoroughly by a competent and skilled individual.

Is There Any Damage to Welds or Beams?

Another thing to watch out for is any obvious signs that a beam has been hit by a forklift or pallet. If you find a damaged beam, it should be replaced, as any damage may cause problems with the integrity and strength of the beam and structure. If there’s only minor damage, it’s important to check welding to make sure there aren’t any cracks.

Are All Connectors and Safety Clips Accounted For?

When inspecting your pallet rack system, it’s important to examine all the clips and connectors to make sure there aren’t any missing or any which are damaged. If you find there are a lot dislodged, you may need to contact the manufacturer to determine the cause, and what needs to be done to correct it.

Are There Any Beams Dislodged from the Upright?

If you find a beam has dislodged or popped from the upright, it’s important to address the issue immediately. A popped beam means that only one end is suspended on one connector. This is a potential hazard, as it could collapse at any time. It’s always best to check all beam ends to make sure they aren’t dislodged.

Working Load Limits

Is There Appropriate Rack Loading?

While inspecting the pallet racking system, it’s important to observe whether there’s enough signage provided by the installer or designer. It also gives you a guide as to whether the rack configurations have been altered or not.

Uprights and Footplates

Are Any Uprights Damaged?

When checking uprights, take notice of any significant damage. If you find any cracks, splits, or twists, it’s important to replace that section or splice in a brand new section to that upright. The equipment manufacturer will need to approve all splices. If you find that the upright is really damaged, it should be replaced, along with the footplate.

Are All Splices in Great Condition?

When inspecting your pallet racking system, it’s important to check that all splices are also taken care of. They shouldn’t be below 1.5m, and should be above the first beam level. There should also be only 1 splice between two adjacent beams.

Out of Plumb

Is All Racking Vertical?

Incorrect installation is one of the major causes of out-of-plumb racking. This is usually a result of heavy impact, settling of the floor slabs, or overloading. If you find any out of order racking, you should contact your manufacturer.


Are Any Racking Braces Damaged?

During inspection, it’s always good to check the racking braces for damage. If you find any horizontal, diagonal, and bent braces, you will need to replace them as soon as possible. The member deviation shouldn’t exceed 10mm from a 1m long straight on either of the planes

Floor Fixing

Are All Appropriate Floor Fixings Installed?

While checking the racking system, it’s important to check to see whether all floor fixing is undamaged, and it’s installed correctly. If you find a damaged floor fixing, it must be replaced, along with the footplate. There should be two anchors at each foot plate.

How to Stop Damage to Your Racking System

To help reduce the damage caused by the pallet hitting the footplate, uprights, or braces, you can install knee height racking beams in the bottom bay. This will help with raising the height of your products and help with manual lifting activities by workers.


If your racking system needs to be inspected, why not follow these helpful inspection tips to make sure you locate all problem areas as they arrive. You could be surprised at how much damage your racking system may or may not have. So, did you find any additional damage in your pallet racking system?