Why You Should Never Drill or Bolt into Pallet Racking Beams

During pallet racking inspections, one of the most common — and most serious — issues we come across is beams that have been drilled into, had brackets bolted on, or have timber boards screwed directly to them. While these modifications might seem harmless or convenient at the time, they can significantly reduce the strength o

f the racking and make it non-compliant with Australian Standards.

Why Drilling or Bolting into Beams is a Problem

Pallet racking beams are designed, tested, and certified to carry very specific loads. The steel profile and welds have been engineered so the load is evenly spread across the beam and transferre

d safely into the uprights.

When you drill into a beam or bolt on brackets, you:

• Weaken the steel profile by removing material.

• Create stress points where cracks or fractures can begin.

• Invalidate the manufacturer’s testing and certification, because the beam is no longer in its original, approved state.

In other words, as soon as a hole is drilled or a bracket added, the beam is no longer compliant and must be replaced.

The Problem with Timber Boards

Another issue we often see is timber boards being screwed directly to the top of beams to create shelves. While it might feel like a practical storage solution, it comes with the same problem: the beam has been modified, which makes it non-compliant.

Screws through the beam can:

• Damage the protective coating, leading to rust.

• Compromise the load capacity.

• Void the system’s certification under AS 4084-2023.

The Correct Way to Add Shelving

If you need to store cartons, small items, or irregular loads, the right way to do it is with support bars or mesh deckingthat sits securely across the beams. These accessories are designed and tested for the system, meaning:

• No drilling or modifications are required.

• The load is spread evenly across the beams.

• The system remains compliant and safe.

Compliance and Safety

The Australian Standard AS 4084-2023 makes it clear that racking must be installed and maintained exactly as designed and tested by the manufacturer. Any modification, such as drilling into a beam, means the component no longer meets the standard and must be replaced.

Ignoring this not only risks compliance but also creates a very real safety hazard. A weakened beam may fail under load, leading to serious damage, injury, or worse.

Final Thoughts

Drilling, bolting, or screwing into pallet racking beams might seem like a quick fix, but it’s a costly mistake in the long run. It immediately makes the racking non-compliant and unsafe, leaving no option but to replace the damaged beam.

If you need shelving or decking, always use the correct support bars, mesh decks, or manufacturer-approved accessories. That way, your system stays safe, compliant, and ready to do the job it was designed for.