USER'S GUIDE FOR
INSPECTION OF DAMAGED
STORAGE RACK SYSTEMS
DON’T WAIT UNTIL IT’S TOO LATE!
TABLE OF CONTENTS
Common Safety Problems.............................................4
Industry Standards.........................................................5
Severe Column Damage................................................6
Horizontal and Diagonal
Strut Damage.................................................................8
Footplate Damage..........................................................9
Anchor Damage..............................................................9
Beam Damage,
Missing or Improper Beam Connectors.......................10
Overloaded Beams.......................................................10
Overloaded Frames......................................................11
Frame To Be Plumb......................................................12
Frames To Be Straight..................................................12
Improper Frame Splice.................................................13
Missing / Insufficient Row Spacers..............................13
Broken / Torn Components..........................................14
Dangerous Repairs.......................................................14
Properly Engineered
Rack Repair Solutions..................................................15
Properly Engineered
Rack Protection Products............................................15
The purpose of this document is to provide owners/operators
a simple, educational pictorial resource to aid in their timely
identification of the most common types of pallet rack damage.
Mac Rak, Inc. assumes no responsibility or liability of any kind as a result of the use
of this guide. All users of this guide agree to defend, protect, indemnify and hold
Mac Rak, Inc., their employees, and their distributors harmless for any claims or losses.
© 2014 Mac Rak, Inc.
All Rights Reserved
No part of this User Guide or any of its contents may be reproduced, copied, modified or
adapted, without the prior written consent of Mac Rak, Inc.
2
INTRODUCTION
Warehouse Pallet Rack Systems are engineered, high performance structures
that are designed to support product loads many times their weight. Each pallet
rack component is designed, manufactured, and tested against rigorous quality
controls. These standards ensure that the rack system will safely perform with
designed load applications corresponding to specific configurations.
Although The Rack Manufacturer’s Institute (RMI) design specifications include
safety factors, these calculations do not consider additional requirements that
are imposed as a result of post-manufacture damage. Therefore, it is critical
that pallet racks be routinely inspected and maintained correctly so they can
continue to perform as originally designed.
Component damage reduces the pallet rack’s carrying capacity and may
ultimately lead to a catastrophic pallet rack collapse. The total cost of a rack
collapse is staggering and typically far exceeds the value of the entire rack
structure and stored product. Even worse, a collapse often times leads to:
• Serious injury or death
• Higher insurance premiums, fines and legal expenses
• Product, equipment and business loss
• Expensive cleanup and replacement costs
This document is by no means intended to replace regular
pallet rack system evaluations performed by qualified,
trained professionals. This document specifically does
not provide any engineering or legal opinion on this
subject matter.
Modifications to pallet rack systems located in geographical
areas that are in danger of seismic activity need to be
reviewed by a qualified professional engineer.
3
MAJOR SAFETY ISSUES FOR PALLET RACKING
INSUFFICIENT F. OVERLOADED POOR H. FRAME
UNBALANCED TO BE PLUMB
SPACE ABOVE BEAMS LIGHTING
LOAD (pg. 10)
PALLET (pg. 12)
J. IMPROPER
FRAME SPLICE
(pg. 13)
INCORRECT
BEAM SPACING
I. FRAME TO
BE STRAIGHT
(pg. 12)
L. BROKEN /
TORN COMPONENTS
(pg. 14)
A. SEVERE BROKEN
COLUMN DAMAGE PALLET
(pg. 6)
E. MISSING OR
IMPROPER BEAM
CONNECTORS B. HORIZONTAL
(pg. 10) & DIAGONAL STRUT
DAMAGE G. OVERLOADED
(pg. 8) FRAMES
(pg. 11)
C. FOOTPLATE
DAMAGE
(pg. 9)
The problems and standards contained in K. MISSING/
IMPROPERLY
this document pertain to all storage rack DESIGNED INSUFFICIENT D. ANCHOR
systems including Push Back, Pallet Flow, AISLE WIDTH ROW SPACERS DAMAGE
(pg. 13) (pg. 9)
Carton Flow and Drive-In.
4
INDUSTRY STANDARDS
Pallet Rack safety is becoming increasingly scrutinized by OSHA, Federal and State
agencies and insurance companies, and comes with substantial legal and moral liabilities.
ANSI/RMI MH16.1 the industry standard for industrial pallet rack has recently been
incorporated into the more general International Building Code. The I.B.C. includes the
requirements and governs the construction of all warehouses in the United States. I.B.C.
standards must be met in order to obtain local municipal building permit approval prior to
construction and upon final completion. Therefore ANSI/RMI 16.1 requirements are now
subject to the same enforcement requirements as the I.B.C.
EXCERPTS FROM ANSI/RMI 16.1
1. The storage rack system operator is responsible for maintenance and repair of
storage systems.
2. Upon visible damage, the pertinent portions of the rack shall be unloaded
immediately and removed from service by the user until the damaged portion is
repaired or replaced.
3. Adjusting beam elevations or operating beyond approved work load limits on pallet
rack frames and or support beams without regard to published manufacturers load
tables is not allowed and will lead to rack failure.
4. Altering / modifying components without the direction of a proper supervisory
engineer is not allowed and will lead to rack failure.
5. Proper aisle width and bay width must be maintained based on storage requirements.
OSHA General Duty Clause - Section 5 (a) (1)
• Employers are required to provide their employees with a place of employment
that is “free from recognizable hazards that are causing or likely to cause death or
serious harm to employees.”
Far too often, damaged rack remains in operation because it is ignored or mistakenly
assumed to be safe. The reality is that many damaged systems are at the critical
“TIPPING POINT” where just one more damaged component, or just one more
seemingly non-significant impact will push the system into collapse. While no official
standards have been adopted in the United States regarding rack damage, we are
referencing the SEMA standards that are enforced throughout Canada and Europe.
DAMAGED RACK IS UNSAFE, DANGEROUS AND UNACCEPTABLE.
It is imperative that management create an environment with operators that
ensures timely reports and immediate remedial action.
Owners/Operators should inspect their pallet rack
systems on a regular basis. Particular attention should
focus on damaged or missing rack system components
listed on the following pages.
5
RACK INSPECTION COMPONENTS
A. SEVERE COLUMN DAMAGE
Damage under beam level Damage above beam level Damage behind beam connector
Ripped column Outrigger damage Closed tube damage
Structural column damage Structural column damage Structural column damage
6
COLUMN DAMAGE INSPECTION CRITERIA
REPAIR
if front to back
deflection is
greater than ½"
REPAIR
if down aisle
deflection is
greater than ½"
Reference Standard:
Columns with rips, tears or deflection
greater than ½" in either the down
aisle or front to back direction must
be repaired.
REPAIR
if corner deflection is
greater than ½"
Corner column damage is relatively more critical than
damage to the front and sides of columns.
Rack damage to free standing single rows is more
dangerous than the same damage on back to back rows
with row spacers.
Helpful Hint:
Inspect both front and back leg columns. Inspect for possible
deformation BEHIND beam connectors as pictured on page 6,
upper right hand corner.
7
B. HORIZONTAL AND DIAGONAL STRUT DAMAGE
Roll formed horizontal strut damage Roll formed closed tube Broken diagonal weld
horizontal strut damage
Missing horizontal struts Ripped / torn horizontal and diagonal Damaged roll form diagonal
REPAIR
if vertical plane of
strut is deflected
greater than ½"
REPAIR
if horizontal plane of strut is
deflected greater than ½"
Reference Standard:
Missing horizontal or diagonal braces, or
braces with any rips, tears or braces with
deflection in either plane beyond ½" must
be repaired.
Helpful Hint:
Any torn, broken or missing welds – the strut must be repaired.
8
C. FOOTPLATE DAMAGE
Sheered footplate Sheered footplate Sheered footplate
Reference Standard: REPAIR
Front and back footplates which are torn, if footplate is twisted
ripped or twisted past ½" require repair. greater than ½"
D. ANCHOR DAMAGE
Missing anchor Loose anchor
Reference Standard:
Each footplate of the upright frame (front and
back) must be anchored to the floor with a
minimum of one anchor or per manufacture’s
requirements per that application. Check for
missing, loose or sheared anchors.
9
E. BEAM DAMAGE, MISSING OR IMPROPER BEAM CONNECTORS
Disengaged beam end plate Missing / damaged beam clips Damaged beam
Helpful Hint:
Reference Standard: O.E.M. beam safety devices may be
Load beams must be secured to purchased and installed or standard
withstand 1,000 lbs. of uplift force. grade 5 bolts and nuts may be used
if applicable. Be sure both the left
and right sides are secure.
F. OVERLOADED BEAMS
Reference Line
DEFLECTION
GAP
Reference Standard: LENGTH OF BEAM = ALLOWABLE DEFLECTION
180
Example: 96" BEAM = .53" ALLOWABLE DEFLECTION
180
Residual vertical deformation should not exceed 20% of normal deflection under load.
Residual lateral deformation should not exceed 40% of the normal vertical deflection under load.
Helpful Hint:
Any beam with visible deformation or cracking of the beam end
connectors must be unloaded and replaced. Be sure beams
are fully engaged and installed with proper safety locks.
10
G. OVERLOADED FRAMES
Reference Standard:
Each manufacturer publishes frame capacity
charts. Applicable information to your system
should be prominently displayed on a placard
at the end of an aisle.
! WARNING ! WARNING
DO NOT CLIMB
ON RACKS Average Pallet Average Pallet
2000 LBS 2000 LBS
Maximum Pallet Maximum Pallet
Report all damage 2500 LBS 2500 LBS
to management
Do not alter the structure without
60''
• Evaluation by a Design Professional, and/or, Average Pallet Average Pallet
• Seeking approval from the Supplier 2000 LBS 2000 LBS
Maximum Pallet Maximum Pallet
2500 LBS 2500 LBS
! CAUTION
MAXIMUM SHELF LOAD 5000 LBS
10''
Conduct regular inspections to check for:
• Proper application and use
LOADING DETAILS
All loads to be uniformly distributed.
• Loads within allowable limits For more info see load application and configuration drawings on file.
• Damaged/disengaged structure or components
25,000 LBS
For questions contact: Maximum Bay Load
ABC Rack Systems
123 Main Street Client: XYZ Warehouse
Anywhere, ST 01234
Project Reference: MacRak Sample
987-555-1234 Date Supplied: 01/10/2014
Placard examples of acceptable format / content
Actual appearance may vary
Helpful Hint:
Be sure capacity plaques include
beam elevations and design loads.
DO NOT CHANGE ORIGINAL CONFIGURATION OR WEIGHT LOAD
WITHOUT ENGINEERING APPROVAL. CHANGES TO THE ORIGINAL
CONFIGURATION CAN CAUSE OVERLOADED FRAMES.
Plaques need to be changed whenever there are modifications
to the rack configuration or load.
11
H. FRAME TO BE PLUMB
Reference Standard:
Maximum top to bottom out
of plumb ratio for loaded rack
is 1/240 (for example ½" per
10’ feet in height). Measured
from the centerline of the
column at the floor to the
centerline of the column at REPAIR
the top of the shelf elevation. if plumb ratio
for loaded rack
Columns exceeding this limit is greater than
should be offloaded and re- TOTAL RACK HEIGHT
plumbed. 240
Damaged parts must be
repaired.
I. FRAME TO BE STRAIGHT
Reference Standard:
Maximum horizontal distance
from centerline at any point
on column to a plumb line
from any other point on the
column cannot exceed ½"
per 10 feet in height.
REPAIR
if plumb ratio
for loaded rack
is greater than
TOTAL RACK HEIGHT
240
12
J. IMPROPER FRAME SPLICE
Improper splice installation Dangerous connections
Reference Standard:
Although splices are an accepted practice, extreme care must be exercised to ensure that splices
are approved by the various frame manufacturers and within their installation and performance limits.
CRITICAL:
All modifications to frames, including frame splices,
must have engineering approval per applications.
K. MISSING / INSUFFICIENT ROW SPACERS
Example of roll formed row spacer Example of structural row spacer
Reference Standard:
Back to back frames need row spacers
positioned a maximum of 10’-0” apart
from each other.
13
L. BROKEN / TORN COMPONENTS
Torn column Torn footplate weld Broken strut connection
Reference Standard:
Any component with broken or
torn welds must be repaired.
M. DANGEROUS REPAIRS
Non-engineered repairs Non-engineered repairs
Improper installation Multiple issues
Reference Standard:
Rack repairs must be approved
by a supervisory rack engineer.
14
PROPERLY ENGINEERED RACK REPAIR SOLUTIONS
Reinforced Column Kit Reinforced Column Kit Single Leg Frame Kit Double Leg Frame Kit
with Outrigger Deflector
PROPERLY ENGINEERED RACK PROTECTION PRODUCTS
Outrigger Protection Bolt-on Column Protector Heavy-Duty Impact Protection End of Row Guard
IMPORTANT FINAL WORD:
When choosing a pallet rack repair vendor be sure that their products
and installation procedures have been reviewed and approved by
a qualified supervisory engineer. Repair solutions and installation
procedures that do not conform to accepted industry standards
may often be as dangerous as the damaged rack component.
15
Engineered
Rack Repair & Protection
Solutions
Mac Rak Inc. repair kits are engineered to the highest standards.
Mac Rak Inc. produces the highest quality, highest future impact protection products available.
Mac Rak Inc. offers a Limited Lifetime Warranty for all our products against defects in
manufacturing or material workmanship. The Advantage, Elite and Bulldog product lines carry
a Limited Lifetime Impact Warranty.
All repair products are powder coat painted. All necessary hardware and anchors are included.
All repair products may be installed without complete unloading of the rack when a rack-lifting
jack is used.
Mac Rak repairs all types of storage racks.
For more information
contact your local dealer,
or contact Mac Rak directly
Ph: 815-723-7400
info@[Link]
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© 2016 Mac Rak, Inc. Mac Rak is a registered trademark of Mac Rak Incorporated. (Information contained in this brochure is subject to change without notice.)