Forklift damage to warehouse racking? Here’s how to prevent it from happening again
A fresh dent at the bottom of a rack upright. An end-of-aisle section positioned just a little too close to the traffic route. Or a driver who repeatedly has very little room to place a pallet correctly.
In such situations, the first instinct is often to install rack protection. But before choosing a product, two other questions are more important.
Is the racking still safe to use? And why was the forklift able to hit it?
Has your racking been hit? Assess the damage first
An impact involving warehouse racking requires attention, even when the damage appears limited.
Warehouse racking supports goods and forms part of a structural storage system. Damage to an upright, beam or other load-bearing component should therefore be assessed before additional protection is installed.
An inspection provides a clear picture of the current condition of the racking and any existing damage. It can then be determined whether repairs are required and which additional protection could help reduce the risk of further impact.
See how damage to warehouse racking is assessed
Learn more about warehouse racking inspections
Then look at how the forklift can come into contact with the racking
Not every rack is exposed to the same type of risk.
An upright in the middle of an aisle is approached differently from the end of a rack row. The direction in which a forklift turns, the available aisle width and the locations where pallets are picked up or put away also determine where impact can occur.
That is why it is important to look at the movement immediately before the impact.
Does the forklift have to make a sharp turn? Is there limited manoeuvring space? Or is the racking positioned directly within the vehicle’s turning radius?
These questions reveal much more than simply establishing that the racking has been hit.
Protect the upright or the entire end of the rack?
The right type of rack protection depends on which part of the racking is at risk of being hit.
Upright protection shields an individual rack upright. Frame protection covers a larger section of the rack end and is particularly suitable for end-of-aisle areas alongside traffic or manoeuvring routes.
The right choice therefore starts with the direction of impact and the vulnerable part of the racking, rather than simply adding as much protection as possible.
View our rack protection solutions
When is plastic rack protection a suitable option?
For warehouse racking, we use flexible plastic impact protection from Raysan, among other solutions.
When the protection is hit, the flexible material helps absorb the impact energy before it is transferred directly to the racking. This makes plastic protection particularly suitable in areas where forklifts manoeuvre close to rack uprights and occasional impact cannot be completely ruled out.
The most suitable solution depends on the position of the racking, the available space and the direction of potential impact.
Sometimes the solution is not more protection, but a different layout
A rack protector can shield a vulnerable point. However, it does not automatically change the route taken by a forklift.
If racking is positioned so close to a corner that drivers have very little room to manoeuvre, installing additional protection may reduce the available space even further. In such situations, it is important to first assess whether the layout itself is contributing to the risk. This may involve the position of the racking, aisle width, turning direction or the way a particular area is used.
Sometimes rack protection is sufficient. In other cases, adjusting the warehouse layout provides a better long-term solution.
Prevent the same racking from being hit again
Damaged racking does not automatically mean that more protection is required. First, it must be clear whether repairs are necessary and why the impact occurred.
We can assess the damage, examine the risk area and advise whether rack protection, repairs, a revised layout or a combination of these measures is the right next step.
Is the same racking being hit repeatedly? Let us assess the situation before the next impact occurs.
Contact us for advice or an appointment.
