Pallet Racking Mistakes

While pallet racking might be easy to think of, there are still a couple of mistakes that can be made along the way. So, if you're intending to maintain, purchase, and implement your racking system, you'll need to take a couple of things into consideration. When your system is in order, your entire warehouse productivity can also be increased. Read on as we dive into the top 8 mistakes and how you can avoid them.

1 - Wrong Design

Within the pallet racking world, there are a ton of alternative storage options as well as different racking styles that can compensate for every possible need that you may have. In the instance where you have little space on the floor, you can use a raised platform model. However, if you're thinking of maximizing your storage options, this isn't the option for you. To help you figure out that matter, check out this Pallet Racking Systems specialist.

If your business is fast-paced and things come and go very quickly, a state-of-the-art dynamic concept is better suited. If the warehouse is filled with unusually sized loads or extra heavy loads, the cantilever is ideal. So, before you jump head in, you'll need to think about your needs and select a configuration that works for you.

2 - Lack Of Future-Proofing Your Plans

Businesses usually grow and eventually expand when things pick up and the same goes for your pallet racking system. before purchasing a system, it's a great idea to think of the future. Most new owners tend to buy what is needed now and don't often think ahead. When you properly plan, you'll reduce the possibility of relying on temporary options.

When this type of business is forced to rely on alternative temporary options, the entire efficiency of the facility is decreased. Making this investment is important if you want to get your business up and running so don't forget to give some thought to the future of the business.

3 - Failing To Establish Your Needs

When you estimate as opposed to calculating the load needing support, you'll easily run into some disasters. However, you can also overestimate the load and end up paying quite a fortune for the system if you never need it. If you decide that more racking isn't needed, you'll also run the risk of dealing with collapses in the warehouse.

Additionally, if you fail to think about the height that can be reached via the forklift, the upper parts of your system may become useless. Even miscalculating the depths of your pallets can leave your entire system being completely useless. As a result of all of these issues, it is advised that you perform the necessary calculations so that your work area is always safe from sudden collapses or wastage.

4 - No Thought Is Given To Equipment

If you're planning to get a new pallet racking system, it should be noted that your additional equipment doesn't need to be new. With that said, it should be kept in mind that completely ignoring this easily sets you back by having to purchase an entire fleet of machinery to suit the conditions in the warehouse. Regardless of your existing machinery, some systems do require special equipment.

So, before you purchase your system, it's best to do some extra research to ensure that everything fits your criteria.

5 - Improper Use And Overloading

When your racking systems are overloaded, you can find yourself dealing with irreparable damages. To prevent this from happening, it's best to inform your staff of the max load capacity of the racking system. If you're interested in providing further clarification, you can even ensure that each shelf displays the load capacity to prevent mishaps and confusion.

Additionally, safe work signs are required in your warehouse. These usually indicate the limits of each system as suggested by the manufacturer. In an effort to keep the environment as safe as possible, all racking systems should be periodically audited.

6 - Avoiding Repairs And Damages

If ever these systems become damaged, the overall structural integrity of the entire systems is compromised. So, if ever you realise that anything is damaged, it should be repaired as soon as possible. Your warehouse should have a designated area where employees can report these issues without them being ignored.

However, regular inspections should be carried out to find structural damages and other issues that may be hiding in plain sight. The sooner these repairs are seen, they can be fixed. So, keep in mind that damages should not be ignored.

Additionally, it should be noted that overloading and even collisions can result in collapses and accidents. In order to reduce the risk of this happening to your system, it should be thoroughly inspected and certified.

7 - Unprotected Racking

If you didn't already know, both material handling and pallet racking are like two peas in a pod. when both are done close to each other, accidents are bound to happen. Accidents can be as small as the corner of the forklift clipping the aisle. Even the smallest form of collision can cause a ton of serious damages to your system.

If your operators are being trained, this form of training can only go so far and forklifts will eventually run into your racking system at some point. However, this can present itself as a huge disaster for businesses. This often leads to downtime and a costly cleanup period.

As such, it is important to protect your racking system. Remember, the life of your business is storing product and both your products and system should be protected at all cost. If you feel that you'll need protection products, there are several protection systems in place to protect your racking system and your staff.

8 - Self Installation

If you're a DIY enthusiast, installing your own racking system is not recommended. In essence, these systems should only be installed by those who are familiar with and know the intricate workings of these systems. If you're thinking of hiring an installation service, this can be done when purchasing your system. Most sellers provide the manpower and knowledge necessary to ensure that your racking system is installed in a professional manner.


As we conclude, we have just looked at the top 8 pallet racking mistakes and how you can avoid them. Warehouse mistakes can occur in the smallest ways. When these occur, it's best to get your systems inspected and repaired as soon as possible. Remember, performing a self-installation is not recommended.