Common Types of Damage Found in Industrial Racking Systems

Common Types of Damage Found in Industrial Racking Systems

Despite their robust design, industrial racking systems that we rely on for efficient and smooth warehouse operations can suffer from various types of damage, posing risks to safety and efficiency.

In this article, we’ll take a look at some of the more common forms of damage that can affect industrial racking and offer advice and guidance on prevention and maintenance to ensure their longevity.

Structural Damage to Racking Systems

Structural damage is perhaps the most severe form of harm that can occur to industrial racking systems. This type of damage can happen when the racking is subjected to impacts from forklifts, improper installation, or overloading.

When structural components like beams or uprights are compromised, it can lead to overall system instability and, in severe cases, collapse.

Forklifts are one of the more common causes of structural damage. A lapse in concentration or misjudgment in distance or speed can lead to collisions with racking components, causing bends, cracks, or other deformities. Overloading is another frequent culprit – this happens when operators place too much weight on the racking, which then causes stress on the structure, leading to warping or failure.

To mitigate structural damage, regular inspections and strict adherence to load capacities are essential. Early detection of bends or cracks will give you the opportunity to make fixes or replacements, ultimately preventing more significant issues down the road.

Corrosion and Rust

Corrosion and rust are also threats to the longevity of your pallet racking systems. These problems arise when metal components are exposed to moisture, chemicals, or other corrosive elements. Rust weakens the metal, causing it to lose its structural integrity and eventually leading to failure.

Factors that contribute to corrosion include high humidity, water leaks, or exposure to harsh chemicals. When rust takes hold, it can spread quickly, compromising the entire racking system. Regular inspections can help identify early signs of corrosion, allowing for prompt treatment and prevention measures.

To combat corrosion and rust, you can use protective coatings on metal surfaces. If you bought your racking system new rather than used, then this is likely already in place so you will only need to keep an eye on it to make sure it remains intact.

Keeping the warehouse environment dry and well-ventilated can also reduce the risk of rust formation. If chemicals are involved in warehouse operations, ensure they are stored safely to avoid accidental contact with racking systems.

Load Capacity and Overloading Issues

Overloading occurs when the weight placed on the racking exceeds its designed limits, leading to excessive stress on the beams and uprights. This can result in bending, buckling, or, in extreme cases, racking collapse. Industrial pallet racking systems are designed and manufactured with very high load capacities in mind – but they do still have limits, and these need to be respected.

Overloading often stems from a lack of awareness or disregard for weight limits. It can also happen when goods are unevenly distributed across the racking, causing localized stress points. To prevent overloading, you should clearly mark load capacities on the racking and ensure all warehouse staff are aware of these limits.

Best practices for load management include evenly distributing weight across the shelves and avoiding stacking goods higher than the recommended limit. Regular training for warehouse employees on proper load handling can significantly reduce the risk of overloading and subsequent damage.

Wear and Tear from Daily Use

Daily operations will inevitably take a toll on racking systems, leading to wear and tear. This type of damage is typically less severe but can accumulate over time, affecting the system’s overall performance. Common signs of wear and tear include scratches, abrasions, and minor dents.

Routine handling, especially in high-traffic areas, contributes to this wear – although it might seem minor, these small issues can worsen if left unaddressed. Regular inspections and maintenance can help identify and rectify wear and tear early, maximising the racking system’s long-term durability.

Improper Installation and Assembly

Incorrect installation and assembly are often overlooked but can lead to significant problems. If racking is not installed correctly, it can result in misalignment, unsecured anchoring, or uneven support, increasing the risk of failure and collapse.

Common installation errors include neglecting to secure racking to the floor or improperly aligning beams. These issues will lead to instability, particularly under heavy loads. Following the manufacturer’s guidelines during installation and employing professional installers should prevent these problems.

Improper assembly can also occur during repairs or reconfigurations. Ensuring that any changes are made by qualified personnel is key for maintaining the system’s integrity and safety.

Damage from Environmental Factors

Environmental factors can have a substantial impact on racking systems. Temperature fluctuations, high humidity, and exposure to chemicals can all contribute to damage, as metal components are particularly susceptible to these environmental changes, leading to warping, rust, or other forms of degradation.

To protect against environmental damage, it’s important to maintain a stable warehouse climate. This can be achieved through proper ventilation and climate control systems. If chemicals are part of the warehouse operations, ensure they are stored and handled in a way that minimizes risk to racking systems.


Damage to industrial racking systems poses significant risks to warehouse operations, as well as the overall health and safety of your personnel. Regular inspections, proper training, and proactive maintenance are key to preventing and addressing structural issues and environmental factors – by taking a comprehensive approach to identifying and mitigating damage, warehouse operators can ensure the safety and longevity of their racking systems.

You can reach out to the team at SEE Racking Inspections to discuss your racking safety: remember – a proactive approach to racking system maintenance is crucial for maintaining a safe and efficient warehouse environment.

What Are Warehouse Storage Solutions, and What Are the Different Types?

Warehouse Storage Solutions

Within the warehousing and distribution industry, we often talk about ‘warehouse storage solutions’ (or just ‘storage solutions’) – but what does this actually mean?

If you’re new to the warehouse world, or if you need a refresher on the key terms, then SEE Racking Inspections is here to help with our comprehensive blog.

What are Warehouse Storage Solutions?

Warehouses are, at their core, expansive storage and distribution areas. Whatever type or types of goods are being handled are typically stored en masse, ready for sending out to the next stop on the journey to the end-user/consumer.

This requires not just storage but also ease of access. It’s got to be easy and quick for warehouse workers to find exactly what they need, in the quantities they need it, and to ensure that stock is rotated as necessary. Warehouse storage solutions are used to ensure that this aspect of the operations is as seamless and efficient as possible.

Understanding Warehouse Storage Solutions

More often than not, equipment like forklift trucks, pallet trucks, trolleys and wheeled cages are used to help with the picking and movement of goods. That means any type of storage solution for the warehouse has to be designed for robust, frequent use.

As these storage solutions often hold particularly heavy weights, can be knocked into or jarred multiple times a day, and are in areas with high volumes of other stock, expensive equipment, and personnel, safety is an absolute priority. Not just any rack of shelving unit is appropriate, it needs to be designed, manufactured, and installed with the expectation that it’s going to be treated roughly. Just one shelving unit collapsing or falling over into another can cause a host of issues – the least of all is interrupted operations and moving through stock loss to equipment damage and, ultimately, injury to staff.

Types of Warehouse Storage Solutions

‘Warehouse storage solutions’ is something of a catch-all term, describing a variety of systems designed to efficiently store goods, materials, and products. These solutions range from pallet racking systems, which are ideal for handling large, bulky items, to automated storage and retrieval systems (AS/RS) that offer precision and speed in managing inventory.

Each solution is designed to cater to different types of goods, whether bulky items, perishable products, or small, lightweight goods. Understanding the available storage options is key to tailoring the warehouse setup to accommodate specific inventory types and operational demands.

  • Pallet Racking Systems: These warehouse storage racks include selective racking for easy access to a wide variety of goods, drive-in racking for dense storage of similar products, and cantilever racking, ideal for long, bulky items.

  • Shelving Systems: Shelving units are suited for smaller items, offering versatile design options and applications distinct from pallet racking, facilitating organized storage and accessibility.

  • Automated Warehouse Systems: Advanced options like AS/RS and carousel storage systems significantly enhance efficiency and space utilization, automating inventory management and retrieval processes.

  • Specialty Storage: For industry-specific needs, specialised solutions are available, including storage for hazardous materials or temperature-controlled units for perishable goods.

Factors Influencing the Choice of Storage Solutions

Which storage solution you choose will come down to a few different factors:

  1. Space Availability: The warehouse’s physical layout and space constraints will impact which type of solution you can have.

  2. Type of Inventory: The nature of the items stored, including their size, weight, and turnover rate, is another important consideration.

  3. Accessibility Requirements: How frequently items need to be accessed should also affect your choice of storage system, as you will want to balance efficiency with operational demands.

Benefits of Optimised Warehouse Storage Solutions

Optimising your warehouse storage solutions should bring a number of advantages – by implementing the right systems, you can significantly streamline operations which leads to a reduction in time and resources spent on inventory management. This optimisation results in a smoother workflow and quicker response times to market demands.

Enhanced efficiency is just one piece of the puzzle; as mentioned, improved safety is another critical benefit. Proper storage solutions minimise the risks associated with manual handling and the storage of goods, contributing to a safer work environment for employees.

Adopting innovative storage options also maximises the use of available space, letting you accommodate a larger inventory. This increase in storage capacity supports scalability, allowing businesses to expand operations without the immediate need for physical expansion.

In essence, carefully chosen storage solutions provide a solid foundation for operational excellence, employee safety, and business growth.

Challenges in Implementing Storage Solutions

Implementing new warehouse storage solutions presents a set of challenges, with budget typically at the top of the list. These storage solution systems are rarely inexpensive, but it’s important to assess the return on investment before ruling anything in or out.

Something else to consider is integration with existing systems, as new solutions must seamlessly work with current operations without disrupting workflow or the ROI will once again be affected.

These challenges (and any others that are more unique to you and your site) will require planning and a strategic approach. Engaging with experienced storage solution providers can offer valuable insights into selecting the most compatible systems. Additionally, phased implementation strategies and pilot programs can help in mitigating risks, ensuring a smoother transition to new storage solutions.


Throughout this guide, we’ve explored the significance of selecting and implementing the right storage systems to enhance warehouse efficiency, improve safety, and maximize storage capacity. It should be clear now that warehouse storage solutions are perhaps the biggest driver when it comes to optimising warehouse operations and fueling business growth – however, fully optimising the warehouse requires strategic planning, careful selection of storage solutions, and an awareness of the latest trends and challenges in the industry.

Check out the SEE Racking Inspections blog for more news and insights, and reach out to one of our expert team-members to discuss your racking safety needs.