Custom Rack Repair Kits for Uncommon Rack Type – A Case Study
Case Study Author: Mike McCue
A medical supplies distributor partnered with REB to address the rack damage present in their distribution center. REB needed to design a special repair kit for a specific type of racking present in the facility. The design not only fixes the damaged rack but also creates a more stable and durable storage system.
- Products: Custom Designed Rack Repair Kits, Standard Rack Repair Kits
- Services: Rack Repair, Design, Project Management, Installation
- Project Location: Rochester, NY
- Number of Projects Completed for the Customer: 2
Concern: Damaged Racking that Requires a Specialty Solution
A national distributor of x-ray machinery and parts moved into a warehouse that came with racking already installed in it from the previous tenant. Due to the age and continued use of the racking by the company, there were multiple sections of damaged racking that needed to be repaired.
There are three main zones of racking in the facility. Each zone had multiple sections that were damaged. Some sections of damaged racking were standard racking uprights, while the other sections of damaged racking had a bridge leg upright.
Bridge leg uprights, shown in the photo below, are no longer a commonly used design, which makes it difficult to get repair kits that match the design.
Solution: Rack Safety Assessment
REB conducted a rack safety inspection of the company’s facility so that they could get a better idea of the damage that needed to be addressed.
In total, REB found 160 sections of damaged racking throughout their system. REB took this information to the company with a scope drawing, which outlined the location of each type of damage along with other safety concerns found. As a result, the company was able to assess all of the safety concerns and identify which repairs they’d like to address.
Solution: Rack Repair for Customer’s Unique Needs
Custom Rack Repair Kits
The bridge legged sections of racking require a specially designed repair kit since a standard repair kit does not fit on the uprights. Unfortunately, the company that manufactured this style of racking no longer made the repair kits for them.
REB’s design team analyzed the racking and designed a rack repair kit that fixes the damaged sections and improves the overall strength of the system.
The custom repair kits use heavy-duty structural tubing and a bullnose design for improved strength and durability. The bullnose design helps the repair kit withstand more force if the racking is hit by a forklift in the future.
The repair kit is designed with the front and back legs as separate pieces, which are bolted together during installation. The design also uses a saddle mount where the frame is connected to the kit. This, in addition to the optimized pinhole placement on the kit, allows the kit to easily and securely connect to the upright.
Upon completion of the design, REB got it stamped and approved by an engineer. This ensures that the design meets all of the safety and design standards and regulations. REB also brought a conceptual kit to the company’s facility, and had it installed to ensure that it met all of their needs and properly fit within the system. The conceptual design was also used to give the company a preliminary quote so they could have a clearer budgetary number.
The company ordered 152 repair kits, which included 18 extra kits for any future damage. This helps cut down on the time it would take for the new kits to be made, allowing for an immediate repair.
Standard Repair Kits
In addition to the custom repair kits, REB identified 26 sections of standard selective pallet racking that needed repairs. These sections could be addressed using REB’s standard rack repair kits, which are designed to accommodate common rack upright profiles.
REB’s standard repair kits feature reinforced steel construction with an additional backer to provide greater strength than the original upright. An extended footplate and floor anchors improve impact and twist resistance, while rigid connection channels provide a secure installation.
Standard kits are available in various sizes and configurations to accommodate different rack designs. Optional features, such as V-nose deflectors, can provide additional protection against future forklift impacts.
Racking Component Replacement
In addition to the repair kits, the company needed some beams and struts replaced. In total, 79 beams and 26 struts needed to be replaced throughout this system.
Rack Repair and Repair Kit Installation
REB’s qualified rack repair installation crew installed the standard and custom repair kits in accordance with ANSI/RMI regulations. The repair process involved the following steps:
- The lower pallets were removed, and the repair area was blocked off.
- Once the area was secure, an engineered rack lifting jack was attached to the damaged rack and pressurized to remove slack and eliminate pinch points. The anchor nuts were then removed.
- The cut locations were measured and marked on the damaged column.
- The damaged column was cut off and removed, one side at a time, finishing with the front.
- The engineered reinforcement channel was inserted and clamped into place.
- Pressure was released from the jack to seat the repair kit against the frame, then reapplied to take the pressure off the kit. The alignment was checked with a level to ensure everything was straight.
- Where applicable, new struts were installed and the columns were anchored. Once secured, the jack and jack head were removed.
Outcome: Safe Warehouse Racking Solution
REB installed 160 rack repair kits, replaced 79 damaged beams, and replaced 32 struts throughout the facility. The combination of standard and custom repair kits allowed the company to address the damaged sections across all three racking zones. Because of this, REB helped the company restore the safety and structural integrity of its existing storage system without having to replace the entire installation.
Improved Facility Safety
Damaged racking can lead to employee injuries and damaged products, making a safe system paramount.
With the sections of damaged racking repaired, the overall safety of the facility is improved. The reinforced design of the rack repair kit will help the system withstand more impact in the event of future collisions, making for an overall sturdier solution.
Future Preparedness
Rather than ordering only the repair kits needed for the immediate project, the company purchased 18 additional custom repair kits to keep on hand. Because the bridge leg uprights are an uncommon design and replacement kits are no longer manufactured by the original supplier, having these extra kits readily available is particularly valuable.
If additional damage occurs, the company can use its existing inventory of repair kits rather than waiting for new custom kits to be designed and manufactured. This helps minimize potential downtime and allows the company to respond to future rack damage more quickly.
More Cost-Effective Than System Replacement
By developing a custom repair solution for the existing bridge leg uprights, REB gave the company an alternative to replacing its racking system entirely. This allowed the company to retain its existing storage infrastructure while addressing the damaged sections and improving their durability.
The ability to repair rather than replace the system helped the company avoid the much larger investment of installing an entirely new racking system.
Simplified Project Coordination with One Partner
Working with REB gave the customer a single contact point for the assessment of their facility, design of the repair kits, and installation of the repair kits. Rather than coordinating separate companies for each phase of this process, the customer could work with the same REB team for design, equipment procurement, and installation.
Have Damaged Racking that Needs to be Repaired?
Safety standards are important to maintain in a warehouse. Adhering to safety regulations helps protect your employees and your inventory. REB Storage Systems can help ensure that your warehouse is safe and up to code by providing the design, project management, and installation expertise to repair and protect your racking and shelving systems.
Contact REB to discuss your rack repair and safety needs, or to develop a storage solution that supports your inventory, fulfillment processes, and long-term growth strategy. Fill out the contact form on this page or call us at (800) 252-5955 to get in touch with a REB representative.
About the Author
Mike McCue is one of REB’s Account Executives. He has extensive experience helping companies evaluate and address rack safety concerns across a wide range of warehouse and distribution environments. Since 2017, he has been involved in over 300 projects that included rack safety assessments and rack repair, serving customers in industries including food and beverage, pharmaceuticals, retail, third-party logistics, distribution, and records storage. His experience helping customers address damaged rack systems and rack systems that lack safety components gives him a comprehensive understanding of how rack safety concerns can affect warehouse operations, employee safety, and compliance requirements.
Mike is an active member in the material handling industry. He has hosted webinars for Modern Materials Handling, has attended/exhibited at MODEX, ProMat, and MHEDA conferences, and is an active participant in educational events and training programs for safety, remediation, and repair
You can learn more about Mike McCue and the projects he has worked on by visiting his profile.
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