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Pallet Rack Installation Safety

Pallet racking is designed to hold large amounts of merchandise in a limited amount of space. While very efficient, the installation of this type of racking requires care and attention to detail. The racking, in its original form, is quite strong, but improper installation can result in changes to the structural integrity of the racking and pose a serious safety risk.

  1. Installer Safety

    • Pallet racking structures have two primary components: uprights and cross beams. The cross beams insert into the uprights, which may be as tall as 24 feet or higher. Workers stand the upright and begin inserting the lower beams. As they move higher, these workers will need to be equipped with fall protection. In general industry, OSHA (Occupational Safety and Health Administration) requires anyone working over four feet off the ground to wear fall protection. In the construction industry, fall protection is required for heights of six feet or more. Workers should also be equipped with gloves and hard hats. The size and weight of the uprights will require a team lift, or the upright must be mechanically manipulated into place.

    Square and Plumb

    • The structural integrity of the pallet racking depends on their proper installation. The racking must be square and plumb. As a general rule, a 1/8-inch vertical tolerance in four feet is acceptable. Each section of pallet racking should be squared and the vertical uprights checked with a level. It is also critical to space the beams properly. Extended areas of uprights with no beams can alter the load capacity of the racking unit. Installers should follow the manufacturer's recommendations for maximum beam spacing. Many beams are equipped with self-locking tabs to prevent them from coming free from the upright. If these tabs are not present, the beams must be bolted to the upright to prevent accidental removal.

    Anchoring

    • Once the racking is squared, the uprights must be anchored into a sufficient concrete floor. Every upright must be individually anchored. The anchor bolts should be 1/2 inch by 5 1/2 inch. Some racking will call for different size anchors, but code calls for a minimum of a 3 1/2 inch embedment. Once the racking is installed and anchored it is ready for use. It is highly recommended that weight limit decals or signs be placed on the racking unit. This limit will be based on the type of upright used as well as the beam thickness. These weight limits should never be exceeded.

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