In a typical warehouse, lift trucks constantly move through tight aisles, placing and removing heavy loads, day in and day out. Eventually, rack damage is almost inevitable. However, many warehouse managers put off repairs until the last minute, unaware of how rapidly seemingly insignificant damage can escalate into a significant safety emergency.

Pallet Rack Repair Basics

Pallet rack repair involves returning damaged racking systems to their initial safety specifications and load capacities. In contrast to complete replacement, repair is a cost-effective solution that can be performed with minimal interruption to warehouse operations. Engineered rack repair kits work with existing racks to renew their safety and original capacity while offering protection against future damage.

The repair process is remarkably streamlined, in many cases up to four times quicker than replacement, and needs 75% less product repositioning. Most repairs can be finished without completely unloading stored inventory, which substantially reduces downtime and operational interruption.

Common Types of Pallet Rack Damage

Understanding the various classifications of damage helps in correctly assessing your warehouse's safety needs:

Structural Damage: This affects the overall security and durability of the pallet rack, often caused by overloading, poor setup, or accumulated minor impacts. Structural damage undermines the entire system's stability.

Impact Damage: The most prevalent type, typically caused by lift truck impacts. According to industry data, about 90% of rack collapses can be linked to equipment impact. This damage usually occurs at the lower portion of the front column of the pallet rack upright.

Non-Visible Damage: Hidden problems like weld cracks, deterioration, or metal fatigue aren't immediately apparent but can seriously compromise rack stability. Scheduled professional assessments are critical for detecting these types of problems.

Safety Hazards and Risks of Damaged Rack

OSHA requires safe industrial racking systems in all United States facilities. When racks are compromised, the potential consequences extend beyond legal non-compliance to critical safety risks.

Compromised racks have diminished capacity and present serious risks of failure and bodily injury. In extraordinary cases, weakened racks can cause catastrophic collapse, threatening workers, harming inventory, and potentially leading to fatalities. Additionally, employers are statutorily responsible for workplace safety under OSHA regulations, making rack maintenance not just a practical consideration but a legal obligation.

Repair Techniques and Best Practices

Today’s rack repair approaches have advanced significantly, offering solutions that are both more effective and less invasive than traditional replacement:

Engineered Repair Kits: Companies like Damotech supply purpose-built kits developed to restore rack integrity. The DAMO PRO and DAMO FLEX are examples of engineered solutions that not only fix damage but shield against future impacts.

On-Site Installation: Most repairs can be carried out on-site without taking out entire rack sections. A repair jack supports the upright while its compromised portion is cut and the repair kit is installed. The best repair kits are bolted on, avoiding the requirement for on-site welding authorization.

Professional Assessment: Before any repair, a thorough inspection by trained professionals is essential. The Rack Manufacturers Institute (RMI) guidelines state that damaged rack should be segregated and examined by a supervising engineer before being worked on.

Choosing a Pallet Rack Repair Company in Tucson

For warehouse supervisors in Tucson, picking the right rack repair company is essential. Raymond West excels as a leading provider in the region, delivering certified Damotech-based rack repair services with a team of over 400 specialists across eight Western states. Our thorough approach features inspection, customized repair kit design, and professional implementation that reduces operational disturbance. By collaborating with Raymond West, warehouse managers acquire access to the industry's most cutting-edge repair options while guaranteeing compliance with safety requirements and protecting their valuable inventory and personnel.

Raymond West's Tucson facility serves Pima County, including Tucson, South Tucson, Marana, Oro Valley, Sahuarita and surrounding areas

Raymond West | Tucson Material Handling Equipment Supplier

Tucson Service Area
(520) 729-4222