Pallet Rack Repair Kit vs. Full Replacement? | Apex Safety Spotlight

Addressing Pallet Rack Repair — Repair Kit or Full Upright Replacement

The lower portion of your pallet rack uprights is particularly susceptible to damage caused by forklift impacts. Even minor bumps and thumps can compromise the safety and usability of your rack system. So, just as you wouldn’t drive an unfit car on the road, your rack is a valuable asset and should be repaired to ensure safety and functionality. With two options — repair or full replacement, it’s sometimes hard to decide the most appropriate next step. The Apex team is here to help you break down the options and to get your pallet rack repair completed and your system safely functioning again.

30,000 Ft View – A Wide Perspective

Frame replacements can be more appealing aesthetically and offer fewer limitations if the user decides to reconfigure or move the racking system in the future. Pallet rack repair kits are designed specifically for the type of damage and damage height, whereas a full upright replacement would be suitable for any type and damage height. 

The cost of replacing a pallet rack column versus repairing it with a custom-ordered repair kit varies depending on the size and type of the pallet rack, the extent of the damage, and the specific repair kit required. Repair kits must be engineered and designed to, at minimum, return the system to the capacity it was designed to maintain by the original manufacturer or certified 3rd party. Generally, replacing a pallet rack frame is more expensive than repairing it with a kit designed for targeted repairs—review lead times and costs for materials, installation, and operational disruption when comparing the options.

Replacement includes the price of the new frame, labor costs for disassembling and reassembling the rack, and any additional expenses related to the installation process. However, a repair kit is a less invasive installation requiring less steel and fewer labor hours to complete… which is why it is generally the more affordable option depending on the complexity of the repair and the supplier or rack manufacturer. 

Pallet rack repair kits can be suitable for rack damage that includes upright dents, twisting, crimping, punctures, and/or missing braces, as well as strut and footplate damage.

Repair Kit Pros Typically shorter material lead time Less labor-intensive installation Does not require full bay offloading May add strength/capacity to the upright Minimal operational disruption Requires less area for materials staging Can add rack guards and internal reinforcement to prevent future damage Larger baseplates create new anchor locations in the slab May not interfere with in-rack sprinklers –doesn’t require disengaging a charged sprinkler pipe Potential to avoid electrical systems integrated within the rack Often more cost-effective

Repair Kit Considerations Could void the manufacturer’s warranty Requires a specialized installation crew trained to handle repairs If additional damage occurs between the time the kit is ordered and installation, the repair kit may no longer be suitable to address the damage Note: If the frame is out of date with code compliance, replace it vs. repair

Time is of the Essence for Repairable Rack Damage

 

When your pallet racking has sustained mild damage, it is often repairable as long as you get to it before it begins to rust or decay –that means time is of the essence. The Apex Rack Repair App is your go-to source for fast rack damage evaluation. 

The Rack Repair App is free to download and use. Simply choose from the pre-loaded specs to capture all the information you need for a proper damage assessment and repair kit order. Upload your findings to the Apex PROs to evaluate your inspection results and quickly supply a cost-effective rack repair solution if necessary. 

Try the Apex Rack Repair App today – FREE on the App Store.

All Apex pallet rack repair solutions are independent; we only provide the most cost-effective resolution for your precise needs. Call today for more information or to schedule a pallet rack inspection and repair.

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