How Water and Chemicals Can Damage the Base of Your Pallet Racking

When most people think about pallet racking safety, they picture beams, frames, and forklifts moving close to uprights. But one of the most common — and most overlooked — issues we find during inspections is corrosion at the base of pallet racking frames and baseplates.

This problem is especially common in industries like food and beverage production, where floors are regularly washed with water and cleaning chemicals. While cleaning keeps your facility hygienic, it can quietly destroy the bottom of your racking if the right precautions aren’t taken.

Why the Base of the Frame Is Vulnerable

The lowest part of the upright — the baseplate and the first few hundred millimetres of steel — sits directly on the floor. This is exactly where water, cleaning solutions, and even condensation tend to pool.

Over time, repeated exposure to moisture and chemicals causes:

• Rust and corrosion on the steel upright and baseplate.

• Compromised anchors, as water seeps into the drilled holes in the slab.

• Loss of load-bearing strength, since corrosion thins the steel.

• Non-compliance with AS 4084, which requires racking to remain in sound structural condition.

Even light surface rust is an early warning sign — if ignored, it can progress to deep corrosion, making the upright unsafe and in need of replacement.

Where This Happens Most

We see this issue most often in:

• Food and beverage facilities that hose down or chemically wash their floors daily.

• Cold storage warehouses, where condensation builds up near the floor.

• Outdoor or partially open warehouses, where weather exposure brings in water.

• Chemical storage sites, where spills or vapours can accelerate corrosion.

How to Prevent Water and Chemical Damage

There are several strategies that can dramatically reduce the risk of corrosion at the base of your racking:

1. Hot Dip Galvanised Frames - Using galvanised uprights and baseplates offers the strongest protection against corrosion. The zinc coating creates a barrier, making them far more resistant to water and chemicals. While the initial cost is higher, it often saves thousands in replacement and downtime over the long term.

2. Protective Coatings - Special anti-corrosion paints and powder coatings can provide some resistance, although they may wear off over time in high-wash environments.

3. Improved Drainage - Keeping floors dry is the simplest solution. Ensuring proper drainage or squeegeeing after washdowns helps stop water pooling around baseplates.

4. Stainless Steel Components (where possible) - In very harsh environments, certain stainless steel racking accessories may be used for added durability.

5. Regular Inspections - The earlier corrosion is spotted, the easier it is to address. Replacing a single upright is far cheaper (and safer) than allowing the entire frame to deteriorate.

What to Do If Damage Is Already Present

If your racking baseplates or uprights are already showing rust or corrosion:

• Do not ignore it. Even if it looks minor, corrosion weakens steel quickly.

• Stop using the affected bays until an inspection confirms whether they are safe.

• Replace damaged frames immediately. Repairs like welding or patching are not acceptable under Australian Standards.

• Consider upgrading to galvanised racking in areas where water exposure is unavoidable.

The Bottom Line

Water and chemical cleaning are essential in many industries, but they come with risks for pallet racking. Corrosion at the base of frames isn’t just unsightly — it’s a serious safety issue that can lead to collapse, compliance breaches, and costly downtime.

The solution is prevention: use galvanised or coated products in wet or chemical-prone environments, maintain good floor drainage, and schedule regular inspections. And if corrosion has already set in, act fast — replace affected frames and anchors before they compromise your entire system.

At the end of the day, a small investment in corrosion prevention is nothing compared to the cost of replacing racking, damaged stock, or worse — dealing with a preventable accident.