When it comes to warehouse storage, pallet racks provide an optimal, easy-to-maintain solution. They’re the most common way of storing pallet loads in the world, and they’re used in the vast majority of warehouses, manufacturing facilities, commercial operations and even retail stores. Whether you’re dealing with selective, pushback, drive-in or other types of racks, the issues are frequently similar.

Safe pallet rack operation involves understanding how to properly use racks; an otherwise safe rack can become dangerous and expensive if used incorrectly. Here are 5 common mistakes people make with pallet racks—and what you can do to ensure you don’t make any of them in your warehouse.

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There are two types of pallet rack capacity to take into account: beam and upright. Getting those capacities right is a critical factor in safe, efficient rack operations, so understanding why they are very different numbers is important.

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Is this an unevenly distributed load? Concentrated load?

Line load? Point load? Load of something really heavy?

We have stressed this before: rack loads aren’t just simple weight vs. structure. The dimensions, shape, and size/density of the load as it sits on storage racks is absolutely critical to safe, effective warehouse storage. Our friends at Nashville Wire recently released an excellent piece that helps define the load types and how you can avoid incorrect or unsafe rack loading.

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When designing pallet racks, people tend to pay attention to the easy parts. Beam capacity is straight math; the capacity of a pair of beams, so long as the load is evenly distributed, the load properly positioned, and the safety clips are installed, is a reliable number. Upright frame capacities are a more complex, as they rely on vertical spacing between levels. Get these factors right, and typically it doesn’t take an engineer to design a safe and reliable rack system.

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We have all seen the spectacular (sometimes humorous), but often horrifying videos of rack collapses. They’re all over YouTube. But what really happens to cause these dangerous incidents?

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There is some confusion about the different finishes that can be applied to a pallet rack wire deck.

Various manufacturers offer different finishes, and you may have need of more than one of them for different types of storage applications. This primer on the common finish options can help you make decisions about your warehouse, load, rack and application.

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To save time, people  sometimes climb pallet racks to pick orders or do other things. This should never happen. While  it’s faster to climb than it is to bring a rolling stair ladder or a forklift in to do it right, it’s dangerous and counterproductive. Do it long enough and there will be injuries.

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Pallet rack is typically safe and easily-maintained storage equipment, whether you are dealing with selective, pushback, drive-in, or other types of rack.  But if you load it wrong, if you don’t inspect and repair/replace damaged components, if you don’t understand your capacities, and if you don’t take steps to ensure your rack isn’t impacted by loading equipment, that safe rack can become dangerous and expensive.

We have created an infographic to help you navigate the most common mistakes people make dealing with pallet racks.  Feel free to share this graphic to any site or other media. It is the first of many infographic posters we’ll be offering to help people operate and maintain material handling equipment.

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Above: how difficult is it to access these sheets?

Sheet metal is one of the most difficult handling challenges out there. It’s simultaneously bulky, heavy, somewhat flexible and prone to damage if handled incorrectly. It often has sharp edges and corners, making it dangerous to manually move and turn. At higher gauges or in bundles, it requires forklifts, cranes or scissor lifts for safe and effective handling. Even a thin sheet, if it’s 4 x 8, can be too much for a single worker to handle.

Yet, sheet metal is commonly used in manufacturing and fabrication, so finding better sheet metal storage and handling methods is key. What can you do to handle it better?

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Pallet racks are frequently subject to abuse, and even the toughest rack will need some cautious handling, processes, guarding equipment, and other help to remain in service. Racks can be overloaded, hit by heavy forklifts, misloaded, and otherwise impacted. Read our quick tips to help you avoid the frustration, expense, and danger of rack damage.

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