Pallet Rack Safety Checklist to Prevent Warehouse Accidents

How to Protect Against Pallet Racking Damage

Nobody wants to see a pallet rack go down. When you’re faced with injuries and damaged products, you’re left with just two questions: “How did this happen?” and “What can we do to keep it from happening again?” This checklist will help you respond to accidents that have already happened and prevent accidents from happening again. Keep reading to learn more about how you can implement pallet rack safety practices in your facility. 

1. Anchor and Protect Your Racks

• Anchor every upright with manufacturer-approved hardware so that racks stay secure. Know and implement OSHA pallet rack anchor requirements to make sure that your racks stay stable under daily use. 

• Add rack guards, end protectors, and column protectors. These will take a hit instead of your uprights. 

• Use pallet stops, row spacers, and backstops to keep racks straight. Investing in rack protection up front saves you in the long run. 

Action step: Check high traffic areas. If your racks aren’t anchored or protected, fix those first before checking all racks in your warehouse. 

2. Inspect and Maintain Your Racks Regularly

• Walk your warehouse each month and look for bent uprights, twisted columns, or braces that seem out of line. 

• Scan aisles for leaning frames. Take note of anything that looks off. 

• Check anchors, bolts, shims, and safety pins. Fix anything that is loose or missing. 

• Watch for rust. Paint can sometimes hide it, but it won’t stop the steel from breaking down. 

Action step: Start a pallet racking inspection checklist. Assign someone to do monthly walkthroughs. 

3. Use Only High-Quality Components

• Don’t mix parts from different rack brands. They may not fit the same way or hold the same weight. 

• Skip “homemade” welds. Unless a certified welder and an engineer are involved, patch jobs only weaken the rack. 

• Get an engineer’s approval before adding new beams and levels and before reconfiguring your rack systems. 

Action step: Keep a reliable rack supplier on call. If you’re close to Wichita, Topeka, Salina, or Garden City, Berry Material Handling offers pallet racking sales, installation, parts, and service. 

4. Keep Warehouse Aisles Clear

• Aisles should be at least three feet wider than your largest forklift. 

• Don’t let pallets, trash, or tools block walkways. Keep all exits open. 

• Mark forklift lanes and pedestrian zones with floor lines and signs. 

Action step: Walk the aisles at the end of each shift and clear whatever is left behind. 

5. Train Employees to Handle Racks Safely

Nine times out of ten, rack damage comes from a forklift. 

• Teach drivers to load from the bottom up. 

• Do not scoot the pallet on the rack. 

• If the pallet is crooked, do not use the upright to guide it into place. 

• Create a culture where rack strikes get reported right away without blame. 

Action step: Add rack safety basics to every new hire orientation and hold refresher sessions every six to twelve months. 

6. Respect Load Limits

• Keep in mind that every level of the rack has a unique weight capacity. 

• Post load plaques on each rack. These will list limits per beam level and per bay. 

• Never go over those numbers. Even one heavy shelf can throw the system off. 

• Place heavy pallets on the bottom levels and lighter items higher up. 

• Spread loads evenly across beams. Avoid concentrating loads in the middle. 

Action step: Walk your warehouse. If you don’t have them, add load plaques to your racks. If you do, replace any missing or unreadable load plaques before the next shift. 

7. Store and Secure Loads Correctly

• Inspect pallets before use. Weak or broken boards can fail once loaded. 

• Wrap or strap items so that nothing shifts once it’s placed. 

• Keep pallets centered on beams with even spacing. 

• Never climb racks or step on decking to fix jams. Use pull tools and call for backup if needed. 

Action step: Stock straps, stretch wrap, and pallet pull tools in every loading area so that crews can secure loads immediately. 

What to Do If Damage Happens

• Unload the damaged rack section immediately. 

• Block off the rack section so that no one uses it until it’s checked. 

• Call a qualified rack inspector or repair provider like Berry Material Handling. They’ll confirm what needs to be fixed or replaced and get the rack back in use as soon as possible. 

Action step: Post a clear damage reporting process in the warehouse. Review it during safety meetings so that everyone knows what to do in case of an accident. 

Checklist of Action Steps

1. Check high traffic areas. If your racks aren’t anchored or protected, fix those first before checking all racks in your warehouse. 
2. Start a pallet racking inspection checklist. Assign someone to do monthly walkthroughs. 
3. Keep a reliable rack supplier on call. If you’re close to Wichita, Topeka, Salina, or Garden City, Berry Material Handling offers pallet racking sales, installation, parts, and service. 
4. Walk the aisles at the end of each shift and clear whatever is left behind. 
5. Add rack safety basics to every new hire orientation and hold refresher sessions every six to twelve months. 
6. Walk your warehouse. If you don’t have them, add load plaques to your racks. If you do, replace any missing or unreadable load plaques before the next shift. 
7. Stock straps, stretch wrap, and pallet pull tools in every loading area so that crews can secure loads immediately. 
8. Post a clear damage reporting process in the warehouse. Review it during safety meetings so that everyone knows what to do in case of an accident. 

Find Pallet Racking & Safety Accessories at Berry Material!

Pallet rack safety practices make a huge difference in your warehouse. By following this checklist, you make sure that products make it to customers on time and that your crew remains safe on the job. If you’ve had an accident (or you’re trying to prevent an accident) and need new pallet racking, Berry Material Handling has a huge inventory. 

Or are you looking for column protectors, guard rails, or other accessories for rack protection? We’ve got those as well. Contact your nearest Berry Material Handling location. Our team can help you find the products that you need to keep your warehouse safe.