Engineered to hold thousands of pounds of stored material overhead, industrial pallet racks allow an operation to maximize its storage capacity. However, these structures are vulnerable to impacts from forklifts and the loads they carry. In particular, the columns — or uprights — facing travel or access aisles are at the highest risk of damage. When damage occurs, it’s critical to address the affected rack component as soon as possible. Among the options are field welding, component replacement, or engineered rack repair kits.

“The Rack Manufacturers Institute (RMI) publishes recommendations for how to properly restore damaged rack to its original load capacity,” noted Eddie Murphy, President of SpaceGuard Products. The company is a member of the Protective Guarding Manufacturers Association (ProGMA). “It’s important to follow their ‘Guideline for the Assessment and Repair or Replacement of Damaged Rack,’ to ensure a safe system.”

Upon discovering rack damage, Murphy said, the system owner should engage a certified engineer who is familiar with rack — or the original rack manufacturer — to inspect the structure.

“This qualified professional will help determine the optimal course of action. They will also oversee the work to ensure that the repaired structure matches or exceeds the original capacity of the system for maximum safety,” he explained.

Exploring the Options for Repair of Damaged Rack

While it may appear to be the fastest solution, field welding steel reinforcement pieces to the damaged uprights can be risky, said Murphy. Welding in an uncontrolled environment could spark a fire. Likewise, welding in the field increases the chance of weld contamination. Additionally, welding processes must occur at specific temperatures and only an individual certified to make the specific weld should perform the work.

“Replacing the damaged components with new ones from the original manufacturer is another option,” he continued. “In certain cases doing so makes the most sense. It can, however, be very time consuming.”

That’s because, depending on the location of the damage, a significant portion of the system may need to be disassembled for the new component to be installed. That process can take months to accomplish, Murphy noted.

“Also, product stored in compromised rack should be removed immediately upon discovering the damage. The facility owner has to find a place for that inventory and loses a percentage of their storage capacity for a period of time. That can be costly, especially in refrigerated or frozen storage spaces,” he said.

“Additionally, some systems are extremely difficult to take apart,” continued Murphy. “For example, systems with in-rack fire suppression, pick modules or elevated work platforms, and rack-supported buildings. Replacing damaged uprights in any of these structurally integrated systems is extremely complex and can sometimes take months.”

For those reasons a third option exists: engineered rack repair kits. These kits allow for removal of the damaged section of a rack column and replacement with new components bolted into place.

About Engineered Rack Repair Kits

To ensure the rack repair kit will return the rack to its original load capacity, a qualified engineer designs it to match the specifications of the system. A properly engineered repair kit could include:

• A thicker or reinforced column.
• A splice at mid-height between the beams and above the damage.
• A splice design that is stronger and stiffer than the original column.
• A stronger frame bracing component extending from the floor to just below the splice.
• A stiffer or thicker baseplate with more robust anchorage.

“For maximum safety, rack owners should verify that the manufacturer of the rack repair kits safety tests the components for load capacity,” added Murphy. “Additionally, some manufacturers engineer safety-tested impact protection into their rack repair kits to help a guard the system from further damage.”

This integrated protection could include either a closed tube of steel inside the upright channel, or a fabricated I-beam positioned behind the column and anchored to the floor, he said.

“Those reinforcements are ideal for drive-in and drive-through rack systems because they integrate into the uprights,” explained Murphy.

Installing Rack Repair Kits

In some instances a specialized lifting system can support the loaded rack structure during installation of the rack repair kit. The lift attaches to the rack column above the damaged section, raising it slightly off the floor, explained Murphy.

“That allows the rack system to remain in place while installing the repair kit on the damaged column. Doing so saves a lot of time while preserving as much storage capacity as possible,” he said. “The installers cut the damaged portion away and bolt the new components to the remaining part of the upright. They also secure the repair kit’s base plate to the floor with new anchors.”

Although most impact damage occurs below the first beam position, the rack repair kit typically extends above that connection point. That, said Murphy, can impede proper re-engagement of the load beam unless the kit’s design specifically accommodates the connection.

Guarding Reduces Rack Damage Risks Post-Repair

After a repair is complete, Murphy advised the installation of protective devices specifically designed to deflect impacts.

“ProGMA members offer protective guarding to shield rack columns from impacts at pick faces and the ends of aisles. Mounting these either on the floor in front of the columns or attaching them directly to the uprights deflects impacts in high-traffic areas,” he said. “These solutions include bollards, industrial facility protection guardrail, kerbing/bumpers, and column protectors.”

Looking to the future, Murphy noted that new, sensor-based technologies are increasingly available. These monitoring systems attach to rack uprights to detect impacts and alert management immediately.

“These systems not only provide an instant notification of an impact vibration, but they also will continue to blink or sound an alarm until an authorized user switches it off,” he said. “A solution like that will help operations identify and address damage much faster. It also forces all personnel to be much more aware of the importance of navigating safely through racks.”

Learn More About Rack Repair and Protection

Looking for more solutions for preventing and repairing rack damage to safeguard both racking and personnel? ProGMA offers a Protective Guarding Search Tool, a comprehensive listing of nearly 40 different solutions — including several for rack.