Racking Maintenance Tips to Protect Your Warehouse and Staff

A racking system checklist is a comprehensive tool that helps assess the condition and safety of industrial storage racks in a facility. It typically includes a detailed list of items to check, including the structural integrity of the racks, the condition of the floor and loading equipment, compliance with safety standards and regulations, and overall maintenance.

The checklist helps to identify potential issues, such as overloading, damaged components, or inadequate repairs, that could compromise the safety of workers and the integrity of the facility’s inventory. By regularly using a racking system checklist, facility managers can proactively identify and address issues, ensure compliance with regulations, and prevent accidents and costly downtime.

Racking System Preventive Maintenance Schedule

Use this schedule as a baseline for regular pallet racking maintenance inspections. Adjust frequency based on usage, rack type, and facility environment.

Weekly

• Walk the warehouse floor and visually inspect racks for obvious damage (dents, missing safety pins, loose components)
• Clear debris or pallets blocking rack bases or aisleways
• Ensure pallet loads are placed evenly and not overhanging

Monthly

• Check for missing or damaged safety clips, bolts, and load labels
• Inspect beam and upright connections for looseness or wear
• Confirm rack protectors and column guards are intact and properly positioned

Quarterly

• Inspect for rust, corrosion, or paint damage (especially near joints and footplates)
• Verify all rack components are level and correctly aligned
• Check that racks are securely anchored to the floor

Annually

• Schedule a third-party inspection by a certified rack safety expert
• Review current racking configuration against actual load types and warehouse layout
• Reassess training and maintenance procedures; update checklists if necessary

Tip: Keep a record of all inspections, repairs, and modifications. This supports safety compliance and simplifies audits or insurance claims.

Racking System Vs Pallet Racking System

A racking system is a structure that is designed to store materials or products in an organized and efficient manner. A racking system can be designed in a variety of configurations, depending on the specific storage needs of the business or organization.

A pallet racking system is a type of racking system that is designed specifically for the storage of palletized materials. This type of racking system consists of horizontal beams and vertical uprights that create levels for the storage of pallets. Pallet racking systems are commonly used in warehouses and distribution centers

Selecting a Pallet Rack System and Maintaining Its Environment

When selecting and maintaining a pallet rack system, it’s critical to consider both initial design suitability and ongoing environmental and safety factors. Below is a combined storage rack system checklist for set up and continued safe use:

Environmental Considerations

• Monitor temperature, humidity, and other factors that could compromise rack integrity (e.g., moisture, extreme heat, or cold).
• Ensure proper ventilation to prevent condensation and buildup of fumes or gases.

Rack Design & Setup

• Select a rack system tailored to your operation’s specific needs, including load type, weight, access requirements, and storage density.
• Confirm that the rack dimensions suit the warehouse layout and allow for safe equipment access.
• Verify that racks are installed level, securely anchored to the floor, and properly spaced for safe loading and unloading.

Regular Inspections & Maintenance

• Establish a routine inspection schedule to detect damage early.
• Conduct visual checks for:
  • Rust, corrosion, or paint wear (especially on footplates, beams, and joints)
  • Dents, cracks, or deformation (e.g., bowed beams, twisted uprights)
  • Loose, missing, or damaged components (bolts, clips, safety pins)
• Inspect rack protectors and guards to ensure they are securely in place, undamaged, and positioned correctly.
• Confirm racks are not overloaded; all items must be within the rated weight capacity.
• Ensure racks remain properly aligned and level over time.

Safety & Operational Controls

• Keep aisleways clear to allow safe movement of people and equipment.
• Provide sufficient lighting throughout the rack area to ensure safe loading and facilitate visual inspections.
• Label all racks clearly with their load capacity and any relevant hazard information.
• Install fire suppression systems (sprinklers, detectors, alarms) in compliance with safety codes.
• Ensure that emergency exits and fire equipment are always unobstructed.
• Ensure proper pallet positioning — loads must be centered, evenly distributed, and stable.
• Verify racks are used according to operational procedures, with no unsafe modifications.

Staff Training & Emergency Readiness

• Train all warehouse personnel on:
  • Proper racking use and load handling
  • Emergency procedures specific to rack failures or collapse
  • Identifying and reporting damage
• Conduct periodic drills and refreshers to maintain awareness.

Tip: Keep maintenance and inspection records for all racks. This supports regulatory compliance and simplifies audits or insurance claims.

Uprights

Rack uprights form the vertical backbone of your storage system and must be kept in excellent condition to maintain overall rack stability. During inspections, check for any bending, warping, or dents, as these could indicate past impacts or overloading. Special attention should be paid to the footplates, which must be undamaged and stable — these connect the entire rack to the warehouse floor and are critical for maintaining upright strength.

Inspect the bracing between uprights for signs of looseness or damage. Bracing ensures the racking system can resist lateral forces, such as those from forklifts or uneven loads. Also, verify that all uprights are properly anchored to the floor and that rack protectors, such as column guards or barrier rails, are in place and undamaged. Rack alignment should be checked regularly to confirm that the system remains straight and level over time. Lastly, ensure that all loads placed on the rack are within the system’s rated capacity and that a formal inspection schedule is in place to identify and address problems before they escalate.

Assembly

Proper assembly of a racking system is crucial to its long-term performance and safety. Begin by selecting the correct type of racking for your storage needs and verifying that all required components — including uprights, beams, connectors, safety pins, and anchoring systems — are present and in good condition. The rack should be installed on a level, obstruction-free surface that allows easy access to stored items and safe forklift maneuvering.

Always follow the manufacturer’s assembly instructions closely. Ensure that vertical uprights are straight and level before securing horizontal beams, and double-check that all bolts, nuts, and clips are fastened correctly. Once beams and shelves are in place, verify that they are evenly spaced and properly seated in their slots. If required, anchor the entire structure to the floor or wall for added stability.

After assembly, inspect the rack thoroughly for any signs of misalignment, missing components, or manufacturing defects. When loading the rack, distribute weight evenly and avoid exceeding the rated load capacity. Periodic post-installation checks should be conducted to ensure that no parts have shifted, loosened, or degraded over time. Following proper assembly procedures from the outset significantly reduces the risk of failure, collapse, or injury later on.

Inspecting Beams

Regular inspection of rack beams is essential to maintaining structural integrity and ensuring warehouse safety. Begin by verifying that the load capacity of each beam matches the weight of the stored items. Overloading, even occasionally, can compromise stability and lead to deformation over time. The spacing and alignment of beams should also be assessed — beams must be level and evenly positioned to prevent leaning instability or uneven load distribution.

Carefully examine beams for any signs of rust, corrosion, or paint damage, particularly at joints and connections. These can weaken the metal and increase the risk of failure. Inspect all welds to ensure they are intact and free from cracks, as damaged welds can compromise the beam’s ability to support weight. Likewise, all clips, bolts, and safety pins securing the beams to the uprights should be present, properly tightened, and in good condition. Missing or damaged fasteners should be replaced immediately.

Inspect for beam deflection by looking for any noticeable bending or bowing, which may indicate that the beam is under excessive stress or has been previously overloaded. Beam length should also be appropriate for the rack’s depth, with no overhangs or protrusions that could affect balance or accessibility. Finally, ensure the beams are compatible with the rest of the racking system; mixing incompatible components can lead to connection issues or uneven load transfer, thereby increasing the risk of collapse.

Safety Measures Before Using a Storage Rack

Clearance

Check that there is enough clearance around the storage racks to allow for the safe movement of workers and equipment. Ensure that there is no overhead obstruction or obstacles that could pose a hazard.

Pallet Positioning

Ensure that pallets are positioned properly on the racks, with the load centered and resting evenly on the beams.

Safety Equipment

Confirm that all required safety equipment is in place and functioning properly. This includes items such as safety harnesses, safety nets, or safety guards.

Load Restraint

Check that loads are properly secured and restrained to prevent shifting or falling during transport or storage. Ensure that straps, chains, or other restraints are in good condition and properly tightened.

Rack Capacity

Confirm that the weight capacity of the storage racks is not being exceeded. Ensure that loads are placed in a way that evenly distributes the weight across the beams.

Rack Stability

Check the stability of the storage racks regularly to ensure that they are anchored securely to the floor and that there is no damage or wear that could compromise their structural integrity.

Load Labeling

Ensure that loads are labeled properly with the weight, contents, and any other necessary information to facilitate safe and accurate handling and storage.

Load Height

Confirm that the height of the loads being stored on the racks is within the recommended limits. Ensure that loads are stacked straight and level to prevent any instability.

Loading and Unloading

Ensure that loading and unloading of the storage racks is done in a safe and controlled manner, with workers trained in proper techniques to prevent accidents or injuries.

Inspections

Conduct regular inspections of the storage racks and all associated equipment, including pallets, beams, clips, and bolts, to ensure that everything is in good condition and functioning properly.

Selecting A Pallet Rack System

Selecting the right pallet rack system for your warehouse or distribution center is crucial to maximizing storage space, improving efficiency, and increasing safety. Here are some factors to consider when selecting a pallet rack system:

Load Capacity

The pallet rack system must be able to safely support the weight of the products or materials being stored. Consider the weight, size, and shape of the loads to determine the necessary capacity.

Storage Density

The pallet rack system should be designed to optimize the available space, considering the height, width, and depth of the rack.

Rack Height

The height of your warehouse ceiling can impact the height of the pallet rack system you choose. You need to make sure the rack system can fit in the space you have available.

Accessibility

Consider the frequency of access to products and whether selective, drive-in, push-back or other rack types are appropriate.

Inventory Management

Evaluate the type of inventory you will be storing and the picking method that will be used to determine the best rack configuration for your warehouse.

Warehouse Layout

Consider the layout of the warehouse, including the size and shape of the building, the location of the loading docks, and the height of the ceiling.

Flexibility

You may need to consider how easily the rack system can be reconfigured or expanded in the future, as your needs change.

Safety regulations

Ensure the pallet rack system meets OSHA safety standards and regulations.

Budget

Determine your budget for the pallet rack system, including the cost of installation, ongoing maintenance, and any necessary accessories.

Future Expansion

Consider the potential for future expansion and the ability to add on to the existing pallet rack system as storage needs increase.

Types Of Pallet Racking Systems

Selective Pallet Rack

A selective rack is a type of pallet racking system that is designed for high selectivity and accessibility. It is widely used in warehouses and distribution centers due to its ease of use. The system comprises vertical upright frames and adjustable horizontal load beams that can accommodate various pallet sizes. The beams can be adjusted in 2-inch increments, providing versatility in the height of the storage levels.

Selective rack is typically made of sturdy steel and can support heavy loads. It can also accommodate pallets of various shapes, sizes, and weights, making it a versatile storage solution for many industries. Depending on the available space and the storage requirements of the facility, the system can be configured as a single row or multiple rows of racks.

Drive-in Pallet Rack

A drive-in pallet rack is a type of pallet racking system that allows for high-density storage of palletized goods. In this system, the forklift operator drives into the rack structure to place or retrieve pallets, eliminating the need for aisles between the racks. This results in a much higher storage capacity compared to selective rack systems. The drive-in rack is designed with continuous rails that guide the forklift into the rack structure and prevent damage to the system. The system is ideal for storing large quantities of the same SKU and is commonly used in facilities with a low number of SKUs but a high inventory volume. However, because of the nature of the system, it can take longer to retrieve pallets compared to selective rack systems, and the risk of damage to pallets and rack structures is higher.

Push-Back Pallet Rack

The push-back pallet rack is a highly efficient storage solution that maximizes warehouse space utilization by providing multiple pick faces while using fewer aisles. It features a stationary rack structure with a nested cart system that slides along inclined rails, allowing pallets to be loaded two to six deep from the front. The push-back rack is available in multiple configurations and can be easily adapted to specific storage needs. This type of system is ideal for warehouses that require flexibility in selection and high-density storage, and where order picking is not necessary from pallets within the push-back racking system. It also offers the advantage of using the First-In-Last-Out (FILO) retrieval method.

Pallet Flow Pallet Rack

The pallet flow pallet rack is a highly efficient storage system that uses gravity rollers to automate the storage and retrieval process. The system works by adding new pallets at the higher end and retrieving them from the lower end as they automatically move forward on the dynamic flow rail. This efficient flow allows for double or even triple warehouse capacity compared to drive-in systems and uses a First-In-First-Out (FIFO) retrieval flow to provide excellent volume utilization. The system requires no energy consumption and can be customized with various accessories to maximize safe and effective distribution. With a range of two to 12+ pallets deep, it offers a significant cost savings in space usage, employee manpower, and utilities, producing an almost solid volume of usable storage space.

Cantilever Racks

The cantilever racking system is an ideal storage solution for large, bulky, and unwieldy items such as tubing, pipes, bars, and lumber. The system comprises uprights/towers, bases, arms, and brace sets and is designed to stand alone without the need for building support. This offers versatility and durability, with a range of customizable options available. The system can be made from multiple types of materials, including roll-formed and structural steel, as well as galvanized for outdoor storage yards or harsh environments. To ensure longevity and safety, regular cantilever racking maintenance is essential, addressing potential issues like arm deflection, base stability, and corrosion.

Double Deep Racking System

The double deep racking system is a cost-effective solution for creating high-density storage and is a variation of the selective pallet rack, with one row of selective racking placed behind another. This system is designed to store more pallets per SKU, usually accommodating two pallets of the same SKU in each double deep slot. It is an excellent option for those looking for greater storage density, have a medium number of SKUs distributed in medium or high volumes, or stock with medium to long shelf life. With its ability to maximize storage space, the double deep racking system offers an efficient solution for businesses looking to optimize their warehouse capacity.

Live Pallet Storage

Live pallet storage is a system that utilizes gravity to function effectively. Full pallets of inventory are placed onto the loading area and are then transported down tracks that are inclined towards the opposite side of the system where a separate loading out aisle is located. This facilitates the first-in, first-out (FIFO) retrieval flow. By employing this system, users are provided with clear aisles that measure between 9 to 11 feet, and it allows for efficient use of space by utilizing a single lane for each stock-keeping unit (SKU).

Carton Flow Pallet Racks

Carton flow pallet racks are a specialized type of storage system that is similar to pallet flow racks, but tailored specifically to smaller products and boxes instead of full pallets. The system uses gravity to transport items from one side of the racking system to the other, allowing for efficient and streamlined picking. Carton flow pallet racks are designed for high-density first-in, first-out (FIFO) inventory flow and can easily be integrated with other systems to create a complete pick module. One of the key benefits of this system is its versatility, as it can be customized with a variety of accessories such as tilt trays and polycarbonate or steel rollers to accommodate different carton widths and shapes. With its efficient and easily customizable design, carton flow pallet racks are an ideal solution for storing faster-moving items and oddly shaped inventory.

Narrow Aisle Pallet Rack

For those seeking an efficient space-saving solution, the narrow aisle pallet rack is an excellent option. These racks are designed to be loaded and unloaded using a side-loading forklift, which enables them to be positioned closer together, creating aisles that can be as narrow as 5 to 7 feet. Typically constructed from high-quality steel and utilizing selective racking, this pallet rack type eliminates the need for pick and deposit stations by allowing order picking machines to pick directly from the pallets. With its streamlined design and optimized use of space, the narrow aisle pallet rack is an excellent choice for those looking to maximize their storage capacity.

Mobile Racking

A mobile pallet rack is essentially a selective pallet rack or cantilever rack affixed onto mobile bases equipped with wheels that move along electronically driven tracks. By shifting along the tracks, the mobile racks provide access to pallets, one aisle at a time. This type of pallet rack system is particularly suitable for high-density storage warehouses that require maximum selectivity and limited pallet movement. With its innovative design and practical functionality, the mobile pallet rack is an excellent storage solution for modern warehouses seeking to optimize their storage capacity.

Mezzanine Racking

Mezzanine racking is a type of storage system that utilizes the vertical space in a warehouse by creating a raised platform or mezzanine level. This additional level is constructed above the existing ground-level storage space and can be accessed by stairs or a freight elevator. Mezzanine racking is typically used to increase storage capacity or to create an additional workspace in a warehouse. The racking system used on the mezzanine level can vary, but often it is constructed from a combination of pallet racking or shelving systems. Mezzanine racking is a flexible and efficient storage solution that can be customized to meet the specific needs of a warehouse, providing valuable additional storage space without requiring costly building expansions or relocation.

Vertical Racking

Vertical racking is a storage system designed to utilize vertical space in a warehouse or storage area. It involves stacking materials or products vertically to maximize storage capacity while minimizing the floor space used. Vertical racking can take various forms, such as shelving units, mezzanine floors, or high-rise automated storage and retrieval systems (AS/RS). The design of vertical racking varies depending on the size and shape of the products being stored and the available space. This type of storage system is particularly useful for storing long or bulky items, as it allows for easy access to individual items while maximizing the use of available space. Vertical racking is a popular choice for warehouses and distribution centers seeking to optimize their storage capacity and efficiency.

Shuttle Pallet Racking

Shuttle pallet racking is a high-density storage system that utilizes shuttle cars to transport pallets within the racking system. This system is comprised of upright frames, horizontal load beams, and shuttle cars that can move pallets within the racking system, eliminating the need for forklifts to move pallets in and out of the racks. The shuttle cars can be programmed to retrieve and deposit pallets according to specific criteria, such as FIFO (first in, first out) or LIFO (last in, first out) inventory management systems. Shuttle pallet racking is particularly useful for warehouses with high volumes of inventory and limited floor space. The system allows for maximum use of vertical space, increasing storage capacity and improving efficiency by reducing the time it takes to load and unload pallets.

Automated Storage and Retrieval Systems (ASRS

Automated storage and retrieval systems (ASRS) are computer-controlled material handling systems that use advanced technology to automate the process of storage and retrieval of goods or materials from a defined storage location. These systems are designed to increase efficiency and productivity by minimizing the need for manual labor in a warehouse or distribution center. ASRS typically consists of a series of racks or shelves, automated storage and retrieval machines (SRMs), and a warehouse control system (WCS) that manages the flow of materials in and out of the system. The system can be programmed to automatically retrieve specific items and transport them to a designated location for retrieval, reducing the time and effort required for manual material handling. ASRS systems are commonly used in high-volume warehouses, distribution centers, and manufacturing facilities to optimize space, improve accuracy, and increase productivity.

Leveraging eWorkOrders CMMS for Effective Racking Maintenance

Implementing a CMMS, such as eWorkOrders, can significantly enhance the efficiency and safety of warehouse racking maintenance. eWorkOrders offers a cloud-based platform that streamlines maintenance operations, ensuring that inspections, repairs, and preventive tasks are systematically managed.

Key features of eWorkOrders include:

• Work Order Management: Facilitates the creation, assignment, and tracking of maintenance tasks, ensuring timely completion and documentation.
• Preventive Maintenance Scheduling: Automates routine inspections and maintenance activities, reducing the risk of unexpected racking failures.
• Asset and Inventory Tracking: Provides real-time visibility into racking components and related equipment, aiding in inventory control and asset management.
• Mobile Accessibility: Enables maintenance personnel to access and update work orders on the go, enhancing responsiveness and record-keeping accuracy.

By integrating eWorkOrders CMMS into your warehouse operations, you can ensure that racking systems are maintained proactively, compliance standards are met, and overall workplace safety is improved. Book a demo today.

Managing Storage Rack Maintenance with CMMS

A CMMS can efficiently manage storage rack checklists by scheduling and automating routine maintenance tasks, generating reminders for due tasks, and standardizing the process of completing checklists. Users can customize inspections and technicians can complete them electronically, with the system automatically generating work orders for issues that require attention. This comprehensive solution ensures optimal maintenance, streamlines processes, saves time, and increases productivity.

For organizations that lack dedicated in-house teams, a professional shelving & racking maintenance service can supplement CMMS capabilities by handling inspections, repairs, and compliance checks on-site.

FAQs

What is OSHA requirements for warehouse racking?

OSHA requires that warehouse racking systems be structurally sound, properly maintained, and used in accordance with the manufacturer’s specifications to ensure employee safety. While OSHA doesn’t publish specific rack design codes, employers must comply with general safety standards (e.g., 29 CFR 1910.176) and industry best practices, such as ANSI MH16.1.

How often should racking be checked?

Racking should be visually inspected at least once per week for obvious damage and undergo a more formal inspection monthly or quarterly, depending on usage. A certified third-party inspection is typically recommended on an annual basis.

What is a racking job description?

A racking job typically involves assembling, installing, inspecting, and maintaining warehouse racking systems to ensure safe and efficient storage and retrieval. Responsibilities may include handling materials, reading layout plans, operating tools or machinery, and adhering to safety procedures.