Pallet racking collapse is the stuff of many warehouse manager’s nightmares – the income lost through product damage, litigation, equipment damage, lost productivity and even the potential loss of life.

Yet it is an almost inevitable part of the busy, sometimes manic pace at which many warehouses run.

Pallet racking can collapse due to many factors. Many are quick to point fingers at the forklift driver who nudges the upright of the rack and leads to the collapse.

The forklift driver may have missed a few refresher courses or not been up to date with the newest clearance distances, but the warehouse manager and rack supplier also have responsibilities to bear. The warehouse manager, is responsible for the health and safety of their employers. This involves and includes the equipment they use and the environment they work in. The structure of the racking must be of the highest quality and integrity. This is where the supplier and the manager have a joint responsibility. The truth is that collapse occurs due to a combination of factors, some of them are:

• Using racking that isn’t fit for purpose
• Use of improper lift equipment
• Carelessness of forklift drivers
• Overloading of existing pallet racks.

Knowing the primary causes of collapse and it’s causes can help nip the problem in the bud, before it leads to a collapse. Other common causes of rack failure include the use of altered configurations, improperly matched combinations and even change in mode of operations.

Addressing the 4 main causes of racking collapse will help any distribution centre maintain a safe working environment for staff and an efficient base of operations.

• The issue of using racking that isn’t fit for purpose should be addressed by management. In a bid to save on costs, used racking may be purchased. Used racking comes is available in different conditions. The purchasing manager needs to carry out due diligence to ensure that the racking that is bought is refurbished and reconditioned to the highest possible standards.

This is also impacted by the type of goods handled. Buying the wrong type of racking in a bid to save money will only lead to rapid degradation and eventual collapse.

• In setting up a warehouse, the aisle widths need to be considered. The fork lift manufacturer should quote aisle widths that offer maximum clearance for manoeuvrability of the lift. Quoting the minimum makes the erroneous assumption that there will be no overhang of pallets on any side. The fork lift should have enough clearance to be able to manoeuvre within the aisles.

• The carelessness of forklift drivers can be minimized through the use of barriers to protect racking, vending machines, conveyor sections etc. These barriers come in all shapes and configurations, and can be placed at locations all around the warehouse. Bollards, corner braces, guard rails, upright column protectors are all examples of pallet racking protection. Guide rails are especially good for use in narrow-aisle warehouses.

Forklift drivers must be professionally trained and must also undergo regular refresher courses.

• Overloading of pallet racks – If you suspect drivers are loading the racks beyond their design load, you can have the supplier inspect them for beam deflection. Palletized loads that look unstable must also be shrink wrapped to prevent getting dislodged.

Regular inspections by qualified assessors can help spot any structural damage that can result in a full-blown collapse. Avoid the inevitable domino effect that occurs with the collapse of a pallet rack. Litigation, loss of productivity and even death, are ominous for any business.

At Monarch Shelving, we supply the highest quality of used pallet racking and sturdy steel barriers.

We can fit out your warehouse, and protect your racking with all the barriers you require. Visit our shop in Oldham today.