Through the course of normal operations, a rack system can be damaged by forklifts and other material handling equipment. Damaged frames have a reduced capacity and present a serious risk of collapse and personal injury.
Pallet rack repair can fix these damages, protecting it from rack failures or collapses. The repair process is often up to four times faster and requires 75% less product movement than replacement.
Read below to find out more about the pallet rack repair process.
When to Utilize a Pallet Rack Kit
If you've noticed damage to your uprights but haven’t fixed it yet, it’s time to start thinking about utilizing a pallet rack repair kit.
ANSI/RMI 16.1 sets forth rack safety standards to follow, including these regarding damage to rack uprights:
- Column damage: Any rips, tears or deflection beyond acceptable limits. Deflection greater than ½” can no longer carry the original rated load.
- Horizontal and diagonal strut damage: Broken welds, missing braces, or braces with rips, tears or deflection beyond acceptable limits.
- Footplate damage: Sheared or twisted beyond acceptable limits.
To learn more about ANSI/RMI rack safety standards, view the video in this section.
The best thing to do to stay in compliance with industry rack safety standards is to conduct an in-house rack safety assessment as well as have a professional one. If any of the above upright damage is found, rack repair could be a viable option for you to make your daily operations safer and compliant.
Rack Repair vs. Rack Replacement
Replacing damaged rack tends to be a very labor-intensive project. All inventory has to be removed from the damaged rack, the bay has to be dismantled, and a new upright or beam has to be installed. This takes time and money.
Repairing damaged rack is a much smoother process. Racks are repaired in place with manufacturer-engineered pallet repair systems. A lifting jack stabilizes the rack while the damaged portion is removed and replaced with a heavier, abuse-resistant upright. By using a pallet rack repair kit, inventory unloading and business disruption are minimized, and the job-completion time is greatly reduced.
Here are some of the benefits of rack repair versus rack replacement:
- Less disruption to warehouse operations.
- Less unloading of products.
- Faster to repair a damaged column vs. replacing frame and reconnecting beams.
- Less dismantling of accessories: wire mesh deck, crossbars and fire baffle.
- Stronger/heavier gauge repair column installed.
- Less damaged product disposal.
- Less likely to create interference / interruption with fire protection and electrical.
The Pallet Rack Repair Process
How can a damaged rack be repaired without the hassle of complete rack replacement? This step-by-step process explains it all in detail.
- The lower pallets are removed and the repair area is blocked off.
- After the area is secure, the repair process will begin by attaching an engineered rack lifting jack to the damaged rack. Once in place, the jack is then pressurized to remove slack and avoid pinch points. Anchor nuts are removed.
- The cut locations are measured and marked on the damaged column.
- The damaged column is then cut off, one side at a time, finishing with the front, and removed.
- The channel is inserted and clamped into place. Channels are engineered inserts that are configured to reinforce the integrity, stability and capacity of the existing pallet racking system.
- Pressure is released from the jack to seal the repair kit to the frame and then re-pressurized to take the pressure off the repair kit. Alignment is checked with a level for any issues.
- Once the column is in place, new struts are added and the columns are anchored. Once anchored, the jack and jack head can be removed.
Rack Repair Kit Features
REB Storage System International’s pallet rack repair kits are made in the USA and comply with the ANSI/RMI Standards 16.1. These pallet repair systems offer the highest protection against impact. Features include:
- Reinforced post section.
- Can be configured with most beam types.
- Extended footplate with ½” anchors for added impact and twist resistance.
- Manufactured using 50,000 PSI minimum yield high strength 12 gauge or heavier steel.
- Powder coat painted to the customers color choice.
- Can be bolted or welded.
Your Next Steps for Pallet Rack Repair
If you have any indication that you’re racking is impaired, it’s time for a professional inspection.
Fill in the contact form or call REB Storage Systems International at 800-252-5955 to schedule an appointment with one of our safety and repair specialists who can perform an inspection of your warehouse. You’ll be provided with repair and ongoing protection recommendations.
At your request, you’ll receive a proposal and a corresponding scope drawing for these services. To learn more about how to identify unsafe racking conditions, visit our rack safety inspections page.
REB has been providing material handling systems to the warehousing and distribution industry since 1962. We understand that not all products fit the typical racking options. Our team of engineers specializes in evaluating SKUs and designing a storage system based on them, giving you a system that uses every available inch of available storage space.