Pallet Racking in Wet Areas: Problems, Risks, and How to Protect Your System

Pallet racking systems are designed to last for many years — but when installed in wet or corrosive environments, their lifespan

can drop dramatically without the right materials or protection. Wet areas are common in industries such as food processing, cold storage, beverage production, and chemical handling. While racking in these environments performs the same function as any other warehouse, the exposure to water, cleaning chemicals, and humidity introduces unique challenges that can compromise both safety and compliance.

Let’s take a closer look at the problems caused by wet environments — and the best ways to prevent corrosion and damage to your racking system.

The Risks of Pallet Racking in Wet Areas

When steel racking is exposed to water or corrosive cleaning agents, it begins to oxidise, leading to rust. While minor surface rust may not seem serious, corrosion at the base plates, uprights, and beam connections can weaken the structure significantly.

Here are the main risks associated with racking in wet or damp areas:

1. Corrosion and Rusting

Constant exposure to moisture causes the protective coatings on racking to deteriorate. Once rust starts, it spreads quickly, especially at the base where water often pools after floor washdowns. This corrosion eats away at the steel, reducing load capacity and structural integrity.

2. Base Plate and Anchor Damage

The base of the racking is the most vulnerable point in wet environments. Rusted base plates and anchors can loosen over time, making the racking unstable and potentially unsafe. In severe cases, the upright may separate from the base, creating a major collapse risk.

3. Contamination Risk

In food and pharmaceutical environments, rust flakes and metal corrosion can contaminate products. That’s not just a safety issue — it’s a compliance problem that can result in failed audits and costly downtime.

4. Hidden Structural Weakness

Corrosion often starts internally where it’s not visible. By the time surface rust appears, the internal steel thickness may already be compromised, making the racking unsafe even if it still looks functional.

Common Environments That Require Extra Protection

Wet and corrosive conditions can occur in several types of facilities, including:

• Food and beverage manufacturing or storage areas

• Cool rooms and freezers (condensation and humidity)

• Seafood and meat processing plants

• Chemical storage areas

• Wash-down zones or hygiene areas with regular floor cleaning

In each of these settings, standard powder-coated racking is not enough to handle the conditions long-term.

How to Prevent Damage in Wet Areas

1. Use Hot-Dip Galvanised Racking

Hot-dip galvanising is the most effective way to protect steel racking in wet areas. During this process, the entire frame and components are dipped in molten zinc, which coats the steel and provides a long-lasting barrier against moisture and corrosion.

For particularly harsh environments, using fully galvanised frames, beams, and base plates ensures the longest possible life span for the system.

2. Galvanised or Stainless-Steel Base Plates

If fully galvanised racking isn’t required throughout the entire system, you can at least protect the most vulnerable areas — the base plates and lower sections of the uprights. Installing hot-dip galvanised base plates provides a strong first line of defence where water tends to pool and cleaning agents collect.

3. Seal the Floor Around Base Plates

After installation, it’s good practice to seal the floor around base plates and anchors. This prevents water from sitting under the racking and corroding the anchor bolts and steel contact points.

4. Regular Cleaning and Drying

Ironically, water from cleaning is one of the biggest contributors to rust. Where possible, ensure that cleaning processes don’t leave standing water around the racking base. Sloped flooring or drainage can help water flow away quickly.

5. Frequent Inspections in High-Moisture Zones

Wet area racking systems should be inspected more frequently than standard racking. Even with galvanised protection, corrosion can still occur over time, especially in joints and connection points. Early detection of rust, damage, or loose anchors can prevent major failures.

Compliance and Safety

Under AS 4084:2023 – Steel Storage Racking, all racking systems must be maintained in a safe and serviceable condition. If corrosion or rust is found, it must be assessed and, where necessary, repaired or replaced. In heavily corroded systems, the affected components are often deemed non-compliant and must be replaced immediately before certification can be issued.

During inspections, we frequently identify racking bases that have rusted through or lost significant structural integrity — particularly in food manufacturing and cold storage facilities. These systems pose serious safety risks and must be addressed immediately.

The Cost of Prevention vs. Repair

It’s easy to look at galvanised racking and think it’s an expensive option — but when you compare it to the cost of replacing a rusted system, lost stock, or downtime due to non-compliance, the investment quickly pays off.

As with most things in warehouse safety, prevention is far cheaper and easier than repair.

Final Thoughts

Pallet racking in wet areas requires special consideration. Moisture, cleaning chemicals, and temperature changes can all accelerate corrosion and reduce the lifespan of your racking. By using hot-dip galvanised materials, sealed base plates, and routine inspections, you can ensure your system stays safe, compliant, and reliable for years to come.

If you operate in a wet or hygiene-controlled environment, it’s worth speaking with a professional about upgrading your racking or implementing corrosion-resistant components. It’s a small step that can prevent serious problems down the track.