Stop Rust in Its Tracks: 3 Essential Steps for Maintaining your Pallet Rack
Rust-Proofing Your Pallet Rack in the Centennial State
Just like kryptonite weakens the Man of Steel, rust can take down even the toughest steel pallet rack. While your Colorado pallet racks might handle the occasional forklift bump, rust is the real enemy that can quietly erode their strength. To keep your racking system in top shape, rust must be stopped—or better yet, prevented—before it causes serious damage.
Rust forms when moisture lingers on steel components, eventually penetrating its way through the rack. In certain warehouse climates, avoiding all moisture contact is nearly impossible. That’s why the first step is protecting the steel with a durable, water-resistant coating.
Step 1 — Add a Protective Layer
Paint is the most commonly used protective coating for pallet racking. It can be applied via spray, dipping, or powder-coating, with many manufacturers offering a range of color options for personalization or alignment with corporate branding.
Apex also offers in-house painting and refurbishing services for both new and used racking components. Our custom paint formula ensures complete coverage and a durable, long-lasting finish.
Galvanization, while more subtle in appearance, is often more resilient in environments exposed to chemicals, freezers, cold storage, or outdoor conditions. When exposed to corrosive materials, galvanized steel corrodes at just 1/30th the rate of regular steel.
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Real World Scenario – Paint vs. Galvanization In a recent inspection, several rows of painted pallet racking were found severely rusted due to exposure to bagged fertilizer. The same customer had used galvanized racking in other facilities, which effectively prevented similar corrosion. This made it clear that switching to a galvanized solution would be the best option to safely restore the damaged racks. Fortunately, the rust only affected the lower-level storage, allowing for the replacement of the bottom uprights with custom-fit galvanized repair kits, minimizing facility disruption and system downtime. The entire process—from inspection to repairs—can be handled with a single call to the Apex PROs. |
Is Stainless Steel an Option?
For specialty environments like cleanrooms or certain manufacturing processes, stainless steel racking might be the best choice. These components are highly resistant to wash-downs, high heat, and humidity, but they come with a hefty price tag and are generally reserved for situations where they’re absolutely necessary.
While applying a protective coating is a critical first step in guarding against moisture damage, it’s equally important to routinely inspect your racking for any spots where the finish has been worn, rubbed, or scraped away. These vulnerable areas are prone to rust and should be addressed promptly.
Step 2 – Rust Assessment & Action
When it comes to pallet rack rust, timing is everything. The key is to catch rust before it begins to degrade the steel. A great way to do this is by conducting regular inspections of your pallet racks. The Apex Rack Repair App is a free tool your team can use to quickly and thoroughly document any rust or other damage found during inspections. The app prompts you to capture photos and essential specifications, allowing our rack experts to assess the severity and recommend cost-effective solutions. Check below for more details on the Apex Rack Repair Program.
Your goal is to determine whether the rust is just surface-level or if it has penetrated the steel. Surface rust can be treated with one of the methods listed below. However, if you notice dark discoloration or etching in the steel, it’s likely compromised. A good rule of thumb is to use 10% thickness loss as the threshold for repair.
Pallet Rack Rust Removal
So, you’ve identified some rust in its early, surface-level stages—what’s the next step?
- One option is to apply a strong acid, like hydrochloric acid, to the affected area. The acid will strip away the rust without damaging the steel beneath it. Once the rust is gone, be sure to apply a fresh coat of paint to protect the exposed metal.
- Alternatively, high-pressure water combined with scrubbing using sandpaper or diamond paper can also be effective for removing surface rust. The key is making sure all traces of rust are eliminated—any missed spots could cause rust to return quickly. As always, finish with a new protective layer of paint.
Step 3 – Recognize When It’s Time to Call the PROs
The Apex PROs are the team behind the Apex Rack Repair App and your first line of defense against rack damage and warehouse danger. The Apex PROs conduct comprehensive on-site pallet rack inspections and maintain your “areas to watch” and repair lists to look for habits or design flaws that can put your team at risk. They also review Apex Rack Repair App inspections conducted by your team.
Once your team concludes the inspection, they upload the results to the Apex PROs. The report is evaluated, and you receive a prompt reply with any measures to address, fix, or replace the damage. All our repair kit solutions are independent and based on the most cost-effective, durable solution.
Download the Apex Rack Repair App today—it’s free and available on both Google Play and the App Store.
