Why Do-It-Yourself Welded Pallet Rack Repair Isn’t Worth the Risk

Warehouse Safety vs. Welded On-Site Pallet Rack Repair

Pallet rack damage is something everyone tries to avoid, yet we all know that accidents happen. Resorting to a DIY repair with the intent to save time and money can actually produce the exact opposite results. We strongly urge you, our reader, to look at what the experts have to say about Do-It-Yourself welded pallet rack repairs.

Don’t Let Whoops Lead to Weld — Here are Six Good Reasons Why

1. 1. Fire risk
   2. Weld contamination
   3. Weld compromised due to Improper ambient temperature
   4. Weld resistance unable to verify 
   5. Structural engineers won’t certify
   6. Rack manufacturer can’t guarantee load rating 

The Rack Manufacturer’s Institute (RMI) notes several concerns with the safety of welding pallet rack to repair the damage, including the fire risk and external forces affecting the process. Other experts add their concerns about the inability to test the weld to ensure that the repair will have the strength of the original rack component. The result is that the rack manufacturer and structural engineer cannot guarantee and certify the repair leaving you in a very vulnerable position. 

Repair or Replace Damaged Pallet Rack?

So, what are the alternatives to firing up the ol’ torch? The two main options are to replace the damaged components or repair them with a custom bolt-on repair kit. 

Replacing the damaged parts is a good option if you can identify the original rack manufacturer and have the original engineering documentation. It is never recommended to mix parts with lookalike rack parts.

A note of caution is that you may have longer lead times for materials vs. a repair kit and the repair itself is more involved. Also, you must fully unload the rack to complete the replacement vs. more localized unloading with a kit repair. 

Replacing Damaged Rack Components

• • Good option to restore rack to original functionality
  • Must know the rack manufacturer and have original engineering plans
  • May encounter longer lead times for replacement pieces
  • Installation requires fully unloading the rack

Bolt-On Pallet Rack Repair Kits – A Dependable Solution

There are many good reasons to choose a repair kit, and perhaps most important is that they are custom fit to your rack specifications and adhere to local building codes and seismic ratings if applicable. 

Repair kit components are manufactured from high-grade steel and designed to match load capacity. The lead time is typically much shorter than replacement parts, and some repair kit manufacturers even offer a lifetime warranty against impact. You should use an experienced installation crew to ensure the completed repair meets engineering requirements for certification. 

Per RMI, after the repair kit installation, the rack manufacturer or third-party provider must update the Load Application and Rack Configuration (LARC) drawing to note all repairs’ fabrication and installation details. It should be signed and sealed by the engineer approving the installation.

Repair Kit Expectations 

• • Repairs should be approved by the rack manufacturer or independent rack system engineer.
  • Rack engineer should certify that the repair is compliant with system design, load capacity, and meets building codes.
  • Custom-fit repair kits bolt to the existing (undamaged) structure and are secured with high shearing capacity anchors.
  • Seismic area repairs should have adjustments such as a thicker, wider baseplate and anchors approved for seismic forces. 
  • Typically, repair kit installations are completed quickly and do not require the rack to be unloaded.
  • Repair kits often have features to protect the rack from repeat damage, such as bullnose or slope leg.

WOI Professional Installation & Turnkey Service

The Warehouse Optimizers, Inc (WOI) team is with you each step of the way to ensure that your warehouse is safe and your operation is running smoothly. Our experienced team evaluates rack damage to determine if a repair is necessary and orders the custom repair kits. The WOI engineers will ensure that your repair kit is up to the task, and our professional installation crew will bring it all home with a safe, expert repair. Our experienced team completes over 300 rack installation projects annually, and 100% customer satisfaction is always the goal.

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

Each member of the WOI team goes the extra mile to achieve 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.

We look forward to the opportunity to prove to you the value included in working with a trusted dealer. Check out our complimentary blog for more information on Buying Your Pallet Rack from a Local Source.