Racking Damage — Common Causes and How to Prevent Them

What causes pallet racking damage in UK warehouses? Forklift impacts, overloading, poor installation and lack of maintenance — and how to prevent each one.

Forklift Impacts

Forklift truck impacts are the single biggest cause of racking damage. Prevention measures include fitting column guards and end-of-aisle protectors, implementing a site speed limit for MHE, marking pedestrian routes clearly, and ensuring all forklift operators are trained and certificated.

Overloading

Pallet racking is designed to carry specific loads stated on the load notice. Exceeding the rated load causes cumulative stress damage that progressively weakens the structure. Every pallet loaded should have a known maximum weight.

Poor Installation

Racking incorrectly installed is vulnerable from day one. Common errors include incorrect floor fixings, frames out of plumb, and beam clips not fully engaged. Using a SEIRS registered installer ensures installation to SEMA standards.

Lack of Maintenance and Inspection

Racking damage not identified and repaired promptly gets worse over time. Regular weekly PRRS checks and annual SEMA inspections catch damage early. Call 0800 654 6955 to book an inspection or repair.