Safe Stacks: 5 Signs You Need an Inspection Now

Your racking system may be the backbone of your warehouse, but when was the last time you checked its spine? 

Pallet rack systems are built to last, but they're not indestructible. Whether due to forklift collisions, overloading, or simple wear and tear, unnoticed damage can put inventory, equipment, and most importantly, people at risk. 

If you're not sure when your last rack inspection was, it might be time for one. Here are five critical warning signs that it’s time to call in the experts.

---

1. Visible Damage to Uprights or Beams 

Even a minor dent can mean major trouble. Bent uprights or cracked welds often signal that your system’s structural integrity has been compromised. This type of damage typically occurs from forklift impact or improper loading. 

What to look for: 

• Dents deeper than 1/8" 

• Twisting or bowing in beams 

• Paint scrapes indicating impact points 

If you spot these, don’t just flag them, prioritize them for your Warehouse Rack Safety

2. Rust, Corrosion, or Moisture Exposure 

A little rust might not seem like a big deal, but over time, corrosion can weaken metal supports and compromise the load-bearing capacity of your racks. 

What to look for: 

• Discoloration or pitting on steel components 

• Water stains near rack footplates 

• Leaky roofs or HVAC units overhead 

Moisture today can become a collapse hazard tomorrow. 

3. Loose Anchors or Missing Hardware 

Bolts and anchors keep everything grounded and connected. If anything is loose, missing, or improperly fastened, the entire structure becomes unstable, especially under heavy loads or seismic activity. 

What to look for: 

• Uprights that shift when touched 

• Loose base plates 

• Missing beam clips or safety pins 

This is a code compliance issue and a safety red flag. 

4. Overloaded or Sagging Beams 

Every pallet rack system has a defined capacity. Exceeding that, whether knowingly or not, can cause beams to sag, bend, or even snap under pressure. 

What to look for: 

• Horizontal beams sagging more than 1/180th of the span 

• Pallets stored higher or deeper than originally designed 

• Labels missing or mismatched with current loads 

When in doubt, check the spec sheet, or let us do it for you. 

5. Layout Changes or Reconfigurations 

If you’ve adjusted your layout without updating your permits, rack specs, or seismic calculations, you may be out of compliance, and unaware of potential risks. 

What to look for: 

• Added or removed aisles 

• New rack types mixed in with old systems 

• DIY bolt-ons or modifications 

Every change deserves a fresh inspection. 

---

Why Regular Rack Inspections Matter - Upkeep on your Warehouse Rack Safety 

Aside from OSHA and local code compliance, proactive inspections save time, money, and liability. An annual professional inspection can catch wear-and-tear issues before they turn into costly accidents. In high-traffic operations, biannual or quarterly inspections may be more appropriate. 

Even minor forklift impacts can compromise the structural integrity of your racking system.

Corrosion around baseplates or footplates weakens load-bearing capacity over time

Safety pins and beam clips are small but essential. Without them, your system is no longer secure.

Need a Trained Eye on Your Setup? 

At Pallet Rack Supply, we don’t just sell systems, we help protect them. Our rack inspections are comprehensive, fast, and code-informed, helping you stay safe, efficient, and up to date. We’ll help you document everything, flag risks, and prioritize repairs. 

👉 Let’s keep your warehouse safe. Schedule a rack inspection today.