It’s Hip to be Square – Ensuring Your Pallet Rack is Plumb and Straight

Steps for Squaring Up Your Pallet Rack – Straight & Plumb

The Leaning Tower of Pisa might be a cool tourist attraction, but I wouldn’t want to replicate it inside a warehouse. Pallet racking structures must be straight, level, and plumb to meet safety regulations and ensure proper use of the structure. A rack system that is leaning or bowed has a reduced capacity and, therefore, is at risk for collapse. You can take several steps to ensure that your storage rack is square and level.

What Causes a Pallet Rack System to Lean or Bow?

First, be aware of what can cause your storage rack to be out-of-plumb or bow.

• Poor installation 
• Unsecured anchor bolts 
• Equipment strikes
• Beam adjustments
• Overloading

Professional rack installation – Hiring an experienced, trained crew will prevent many safety risks. A trusted team ensures the rack is plumb and straight throughout the installation process. In addition, they properly secure the anchor bolts and shims required for rack stability. 

You can’t do better than the WOI team for warehouse systems installation — we are laser-focused on the safety of the rack system, our crew, and your team members during the process. We follow strict guidelines that ensure a safe workplace during the building process.

Anchor bolts – Rack anchors must be properly installed, but they can still come loose over time. It is one of the reasons that it’s essential to schedule pallet rack inspections. Regularly inspecting the rack system for damage, misaligned pallets, overloaded beams, and other safety concerns will help you catch a risk before it becomes a tragedy. Note: warranty and capacity rating is voided for unanchored racks.

Equipment strikes – Forklift collision damage or even pallet loading and unloading strikes can compromise the integrity of the rack structure. Strikes must be attended to immediately to assess the severity of the damage and sometimes require unloading the rack to await repair. 

Beam adjustments – While inventory specs are known to change, it isn’t always as simple as moving beams around to accommodate the new inventory. Doing so can seriously compromise the safety of the pallet rack system by creating unsupported spans and or causing bowing or leaning under unbalanced load pressures. Always consult a systems expert before making rack adjustments and re-rate the capacity based on the new rack layout and configuration.

About RMI and Building Codes

In spite of being a standalone structure, the safety of an industrial steel storage rack’s design and installation is nearly always vetted by one or more local jurisdictions — including state, county, or local municipality. The reason? The International Code Council’s International Building Code (IBC) is the base code standard by the majority of governing bodies in the U.S. The IBC references RMI’s ANSI MH16.1: Specification for the Design, Testing, and Utilization of Industrial Steel Storage Racks (in section 2209.1) as the standard for safe design and installation of steel storage racks.

The IBC includes industrial steel storage rack within its standards because the safe design, manufacture, and installation of such structures depend on building-specific factors. These include flooring, soil classifications, anchoring, load type to be stored, handling equipment, and more. If the racking is located in an area with any potential for earthquakes, seismic requirements are also considered

Defining Out-of-Plumb & Out-of-Straight

RMI provides the following guidance specific to out-of-plumb and out-of-straight measurements:

Out-of-Plumb Ratio – Maximum horizontal distance (inches or millimeters) from the centerline of the column at the floor to a plumb line that extends downward from the centerline of the column at the top shelf elevation divided by the vertical distance (feet or meters) from the floor to the top shelf elevation.

Out-of-Straight Ratio – Maximum horizontal distance (inches or millimeters) from the centerline at any point on the column to a plumb line from any other point on the column divided by the vertical distance between the two points. A bow in the upright column, for example, could cause the rack to be out-of-straight.

When examining these measurements, the higher the ratio, the greater the possibility of rack failure. Therefore, RMI limits the ratio for both out-of-plumb and out-of-straight to 1/240 or 0.05” per one foot of height (1.25 mm per 0.3 m) or 0.5” per 10’ (12.5 mm per 3 m) of height.

And yes… both measurements are critical to rack safety. Your rack system is vulnerable, particularly at the bottom of the columns where forklift strikes tend to happen, but that is not the sole location. For example, columns can meet plumb requirements from top to bottom and yet be out-of-straight in the middle.

Pallet Rack Inspection

Inspect racking and connections regularly to prevent rack failure. Inspections and corrections of any findings will assure the integrity and safety of the rack, assuring the safety of associates and visitors.

If you’re looking for someone to give it to you straight about the safety of your pallet rack system, the WOI team is here for you.

Straight Talking & Building with Warehouse Optimizers, Inc.

We are a leading material handling source in the Southeast. Our team comprises industry experts who guide you through each phase of your project… and deliver turn-key results. 

With WOI, you receive initial consultation and design support through engineering, permitting, and professional installation.

We rely on our own full-time, trained crew for expert installation services. This dedicated crew installs over 300 projects per year and always strives for safety and 100% customer satisfaction.

WOI Installation Team

• Industry Experienced Installation Teams
• OSHA Trained & Certified
• Certified Drug-Free Workplace
• Licensed General Contractor
• Job Safety Analysis
• Forklift, Scissor Lift, and Aerial Lift Operator Trained

The WOI team goes the extra mile for 100% Customer Satisfaction with our Total Satisfaction Experience. Our commitment to you:

WOI 5-Step Total Satisfaction Experience™

1. We will listen to your needs
2. Execute your project with particular attention to your unique application
3. Stick to project timelines
4. Ensure a safe environment
5. Pay close attention to the detail  of the finished product

Call today to schedule a free consultation and site inspection. Dial (865) 540-4004 or email info@warehouseoptimizers.com for prompt service. We proudly serve customers throughout the Southeast, including KENTUCKY, TENNESSEE, NORTH CAROLINA, ALABAMA, AND FLORIDA.