Learn about Rack repair
Rack repair fixes damaged uprights, the most common type of safety concern found in warehouses. This can include damaged posts, damaged struts, or a combination of both. This damage typically occurs when forklifts hit the upright while turning down an aisle or loading a pallet into a bay.
Since the rack system is engineered into one structure, even slight damage can compromise the integrity of the system. Therefore, addressing damaged uprights is critical.
An alternative to replacing a damaged upright is repairing it. Rack repair is an alternative to replacing a damaged upright. It removes and replaces only the damaged portion of the upright. This results in less unloading and operational downtime.
RCS is a woman owned and operated, WBE certified company that offers professional rack repair services. Our rack repair service complies with all rack safety regulatory requirements. Read below to learn more about rack repair.
Why Choose Rack Repair
Over Rack Replacement?
Because the rack system consists of many components engineered together, replacing damaged uprights is often a time-consuming process of unloading many bays, dismantling the rack, and reconstructing a large portion of the system.
However, rack repair removes and reinstalls only the damaged portion of the rack. This results in the following benefits over rack replacement:
01 Less downtime for warehouse operations
02 Unloading of fewer products.
03 Less dismantling of products integrated into the rack system, such as decking and crossbars.
04 A stronger, more abuse-resistant product is installed.
05 Less likely to create interference with fire protection and electrical.
How the Rack Repair Process Works
01 Step One
First, our rack safety team identifies which uprights require repair through our rack safety inspections. Once the damage is identified and repairs are approved, our installers return to the site to complete the repairs.
02 Step Two
Product should be removed from the bays as necessary prior to the repair. The number of bays to decant is dependent on the height of the damaged location.
Once products are removed, the rack is unbolted from the floor. The installer then lifts the rack via a special jack.
03 Step Three
The damaged portion of the rack is then cut off. Which parts of the upright that are removed may differ, dependent on the scope of the damage. For example, sometimes only one column is damaged, whereas other times both the columns and struts are damaged.
04 Step Four
The corresponding rack repair kit is then installed to the existing rack upright. Alignment is checked, and the rack is anchored back into the floor.
The result is a damage free, code complaint upright that is stronger than the original.
Rack Repair Kit Options
for all Types of Rack
Roll Formed Steel Rack Kits
- 10-gauge steel construction.
- Standard sizes range from 24″ to 84″ in 12″ increments.
- Small size of 6” is available.
- All bolted installation with Grade 5 hardware.
- 1/4″-thick steel connection channels for rigid installation.
- 4″ x 12″ x 5/16″-thick footplate.
- Installs with two 3/4″ diameter anchors to eliminate column twisting.
- Over 12 punch patterns available.
- High-quality powder coat finish.
Available in custom heights and colors.
Custom/seismic footplates available.
Optional 1/4″-thick x 12″ high V-nose deflector for increased defense against forklift damage.
Optional heavy-gauge, flush-welded deflector available for improved aisle clearance.
Structural Steel Rack Kits
- Structural, 1/4″-thick closed-tube design.
- Our strongest single column repair kit.
- Available in 3″ or 4″ column widths.
- 4″ x 12″ x 5/16″-thick footplate.
- Custom/seismic footplates available.
- Optional 1/4″-thick x 4″ high V-nose deflector provides increased defense against forklift damage.
- High-quality powder coat finish.
- Custom heights and colors available.
RCS is a team of experts who
are well versed
in Rack Repair
Combined years of experience project managing material handling systems
Combined years of experience engineering material handling systems
Combined years of experience implementing material handling system safety regulations
Case Studies and Articles
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Contributing Authors: Lori Palmer and Joe Kane Services Provided: Lighting relocation, fan relocation, fire alarm system relocation Location: Fort Worth, TX Concern: Problematic lighting and fan placement in existing warehouse An IT company was working with a material handling systems integrator to build a new selective rack system. The system would hold pallets of IT […]
Frequently Asked Questions
The Occupational Safety and Health Administration (OSHA) has specific regulations regarding pallet racking systems. OSHA requires that pallet racking be designed, installed, and maintained in accordance with industry standards to ensure worker safety. Some of the OSHA standards include properly anchoring the racking system to the floor or wall, ensuring adequate clearance between the racking system and other structures or equipment, and ensuring that the racking system can withstand the loads it will bear.
The lifespan of pallet racking depends on several factors, including the type of racking system, usage, environment, and maintenance. Generally, a well-maintained racking system can last for several decades. However, the lifespan of a racking system can be affected by factors such as the weight and frequency of loads, the type of forklift used, and the level of humidity in the environment. It is recommended that warehouse racking be inspected at least once a year by a qualified inspector to ensure the system’s continued safety and stability.
In our experience, a pallet rack can collapse due to various reasons, including overloading, impact damage, lack of maintenance, and improper installation. Overloading can cause the system to exceed its weight capacity, leading to structural failure. Impact damage, such as from forklift collisions or dropped loads, can also compromise the system’s stability. Lack of maintenance, such as failing to replace damaged components or check for rust or corrosion, can weaken the system over time. Lastly, improper installation, such as incorrect or incomplete anchoring, can also lead to collapse.
We have helped our clients prevent racking collapse by conducting regular inspections to identify and repair or replace damaged components. Overloading should be avoided by adhering to the system’s weight capacity, and workers should be trained on proper use and handling of the racking system. Additional safety measures, such as installing column protectors, safety bars, or safety nets, can also add an extra layer of protection against collapse. It is also important to have a maintenance program in place that includes regular inspections, cleaning, and repair or replacement of damaged or worn components.
The most common causes of racking collapses are overloading, impact damage, lack of maintenance, and improper installation. Overloading, which causes the system to exceed its weight capacity, is a leading cause of collapse. Impact damage from forklift collisions, dropped loads, or other accidents can also weaken the system’s structure. Lack of maintenance, such as failing to repair or replace damaged components, can lead to gradual weakening of the system over time. Lastly, improper installation or use of damaged or incorrect components can also compromise the system’s safety and stability. It is important to regularly inspect racking systems to identify potential hazards and take appropriate corrective actions.
Contact RCS for Professional Rack Repair Services
If you have damaged racks, contact RCS to schedule professional rack repair.
Contact RCS for more information. We work with end users, manufacturers, dealers, and contractors.
Our team will be happy to help you better understand our services and provide you with a quote.