How to Evaluate Pallet Rack Deflection for Uprights, Struts, & Beams | Apex Safety Spotlight
Your pallet rack system supports a maximum load capacity. Each component is connected to work in tandem to deliver safe inventory storage. When conducting routine pallet rack inspections, it is important to look for deflection in uprights, beams, and struts. It’s a little harder to detect vs. more obvious system damage resulting from equipment strikes, but it is no less dangerous.
Deflection refers to the degree to which a structural or roll-formed component is bent or displaced under a load. A certain amount of deflection is considered safe, but the line is thin between allowable and dangerous. Per the Rack Manufacturer’s Institute (RMI), the process for measuring for allowable beam deflection is as follows:
Pallet Rack Upright Deflection
When assessing upright damage, look for any deflection or bend in the upright column greater than ½ an inch. Inspect the upright from front to back, down aisle, and at the column corners. If the deflection gap measures greater than 1/2 an inch at its widest point, consider the upright damaged and report it to management for unloading. If there is a separation between the column and seismic backer, note that as damaged as well.
Upright Deflection:
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Corner Deflection:
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Strut Defection:
Struts play a critical role in the structural integrity of the pallet rack system. When assessing strut deflection, check to see if the strut bows more than ½ inch. Most often, strut damage will occur in the lower portion of the upright.
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Pallet Rack Beam Deflection:
Pallet rack beam deflection is identified by bowing of the beam. Deflection is typically a result of overloading the rack.
Measuring beam deflection – Divide the length of the beam (from the inside of the columns) by 180. In the example above, the 96″ beam length is divided by 180 for a result of .53, or about a ½ inch. If the deflection gap is equal to or greater than ½ inch, the beam is considered overloaded and unsafe.
All Signs Point to Load Plaques for Safe Pallet Rack Capacity
The best way to confirm that your pallet rack system is within the intended load capacities is to check the load plaque. Load plaques should be displayed at the end of each aisle for each system. Strict adherence to the load plaque will help avoid deflection and improve overall warehouse safety. The manufacturer supplies load plaques unique to each system design. The load plaque will detail:
- The maximum permissible unit load (the combined weight of product and its storage container or pallet) and/or maximum uniformly distributed load (UDL) per level.
- The average unit load (calculated as the maximum total weight of product expected on all beam levels in any row, divided by the number of beam levels in that row), if applicable.
- The maximum total load per bay
- Indication of storage levels that support stacking of multiple unit loads
If you are concerned about upright, strut, or beam deflection in your pallet racking system, we recommend downloading the Apex Rack Repair Mobile App to guide you through a proper rack inspection. The app is Free to download, and it connects you to the Apex PROs, who will review your inspection findings, provide a thorough damage report and custom repair solution if needed. Learn more about the Apex Rack Repair App below.
Two Ways the Apex Rack Repair App Protects Your Operation
- Self-guided pallet rack inspection using the app
- Call the Apex PROs for complete inspection and warehouse safety review
Do It Yourself – Download the app. Inspect your racking system using the app to capture all relevant details for each damaged location. Evaluate the entire system, including columns, struts, baseplates, anchors, and beams.
The app is easy to use and prompts you with point & click features and 3D graphics to help ensure you accurately identify each rack element. Upload your report at the end of your audit. The Apex PROs will evaluate your findings and provide a custom repair kit solution if needed.
Would you rather leave pallet rack inspection to the PROs? The Apex PROs are certified rack inspectors that come to your facility and conduct a thorough audit and warehouse safety assessment using the Rack Repair Mobile App.
Apex Guarantee – Whether you’re using the App or working with the Apex Pros, we guarantee you will receive a comprehensive rack inspection report with an independent solution recommending steps for system repairs and maintenance.
Join the Apex Safety Program today and download the Rack Repair Mobile App for free from the App Store. Call us or visit our website for more information.
