The Most Common Racking Damage We See (and How to Avoid It)

Pallet racking takes a beating in busy warehouses. Forklifts, heavy loads, and constant movement all add up — and over time, small knocks can turn into big problems.

During our inspections, we see a few types of damage pop up again and again. The good news? Most of them are easy to prevent once you know what to look for.

1. Bent or Damaged Uprights

This one’s at the top of the list. Forklifts brushing or bumping uprights can cause dents or bends that reduce the rack’s load capacity.

Why it matters: Even a small bend can compromise the structure and increase the risk of collapse.

How to avoid it: Use column guards or bollards, and make sure operators are trained to approach bays square-on — not at an angle.

2. Damaged Beams

We often find beams with dings, twists, or signs of overloading. Sometimes people even try to “straighten” them — which is never safe.

Why it matters: Damaged beams can fail suddenly under load.

How to avoid it: Never overload bays, and replace any beam showing visible distortion or cracking paint (a sign it’s been stressed).

3. Missing or Loose Beam Locks

It’s easy to overlook beam locking pins, but they’re vital for holding beams securely in place.

Why it matters: Without them, beams can dislodge if a forklift nudges a pallet from underneath.

How to avoid it: Keep spares on hand and include them in regular housekeeping checks.

4. Rust and Corrosion

Water leaks, cleaning chemicals, or outdoor storage can lead to rust — especially at floor level or base plates.

Why it matters: Corrosion weakens the steel and spreads quickly.

How to avoid it: Keep floors dry, repair leaks fast, and touch up protective coatings when needed.

5. Missing Bolts or Damaged Base Plates

We still find frames that aren’t properly anchored to the floor — or bolts that have loosened over time.

Why it matters: Unanchored racking can shift under load or impact.

How to avoid it: Make base plate checks part of your routine inspection and replace any missing bolts immediately.

The Bottom Line

Most racking damage starts small — and that’s exactly when it’s easiest (and cheapest) to fix.

Regular inspections, good housekeeping, and a bit of awareness go a long way in keeping your warehouse safe and compliant.

If you’re unsure about the condition of your racking, book an inspection with our team. We’ll help you spot the issues before they become costly problems.