Identifying Pallet Rack Beam Damage | Apex Companies Safety Spotlight

Warehouses are busy, with lots of moving, heavy parts. So what do you do when all that activity causes pallet rack beam damage? This Safety Spotlight takes an U-P-R-I-G-H-T approach to ensuring you know how to identify beam damage in order to prevent potential safety issues. Take a look and consider downloading our Rack Repair app to help you and your team evaluate system damage and determine necessary repairs.

Contact the Apex team for more on pallet rack safety and repair: https://apexwarehousesystems.com/contact-us/
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Read the blog excerpt below:

There are many moving parts in a warehousing and distribution operation, but what happens when one of those moving parts unexpectedly interacts with one of your motionless parts… specifically, how should you address pallet rack beam damage? This Safety Spotlight takes an U-P-R-I-G-H-T approach to ensuring beam safety.

U – Understanding the Basics:
Apex Pallet Rack Training Video - ComponentsThe shelf beam connects to the upright columns to form a “shelf” on which to place the pallet. In order to create the “shelf” you must have a properly connected beam to both the front/rear column of the upright on both the right/left side of the bay. Shelf beams can be manufactured in both structural and roll-formed steel and can come in many different lengths and capacity strengths. Take a look at our Rack Training Video for more pallet rack component and accessory details.

P – Pins, Clips & Connections:
Roll-formed and structural systems are uniquely designed and therefore have different upright to beam safety lock mechanisms. The structural beam is traditionally connected with 2 bolts per side, though certain proprietary designs allow for a single bolt per side. When inspecting for beam damage, check that the bolted connections are in place, tight and secure.

R – Rack Accessories:
Inspect any rack accessory that is attached to the beam to see if it has sustained any damage. Rack accessories can include decking, carton or pallet flow rails, push-back carts, pallet supports, safety bars, dividers, etc. Repair or replace damaged components to ensure safe and effective operation.

I – Inspect:
Visual Inspection should be a regular function but what are you looking for when you’re specifically inspecting your rack for beam damage. Check that beams are still fully engaged in the upright frame. Confirm that the beam is secured with safety locks and that the safety locks are in good shape.

Any beam with visible deformation or crack of the beam end connectors should be unloaded and replaced.

Check to see if the load is properly positioned and that the flue space is clear
Check to see if the beam is bowing under pressure. This is referred to as deflection and requires confirmation with a proper measuring tool, see beam deflection below.
Check each rack accessory for collateral damage.

H- Horizontal:
Beam Load Deflection is a critical safety element with or without a rack strike. Deflection refers to the degree to which a structural or roll-formed beam is displaced under a load. The reference standard (per the RMI) for allowable beam deflection is as follows:

Length of beam/180 = allowable deflection / E.g. 96″ beam/180 = .53” allowable deflection

To confirm load capacities for the racking system, check the load plaque. Strict adherence to the load plaque will help avoid deflection and overall warehouse safety. The load plaque is provided by the manufacturer or installer and will contain:

The maximum permissible unit load (combined weight of product & storage container or pallet) and/or maximum uniformly distributed load (UDL) per level.
The average unit load (calculated as the maximum total weight of product expected on all beam levels in any row, divided by the number of beam levels in that row), if applicable.
The maximum total load per bay.
Indication of storage levels that support stacking of multiple unit loads.

T – Tools:
There are a few simple tools that you will need to conduct your beam safety assessment:
Tape measure/Laser
Load plaque
Writing tool or mobile device

This Safety Spotlight can be used as a helpful guide as you conduct a beam damage & safety examination, but download the FREE Apex Mobile App to simplify the process for any necessary repair and replacement parts ordering.

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