Don’t ignore the warning signs - 5 Red Flags Your Warehouse Racking Needs Attention
A well-designed racking system is the backbone of any warehouse operation — providing the structure, stability, and safety required to keep materials moving efficiently. But like any engineered system, racking components are subject to wear, damage, and fatigue over time. Left unchecked, small faults can quickly escalate into serious safety risks, costly downtime, or even full system failure.
Understanding when your warehouse racking needs maintenance, repair, or replacement is essential to protecting your team and keeping your operation running smoothly. Below, we explore the five most common warning signs that your storage system may need attention.
Rust & Corrosion:
The Silent Structural Killer
Steel corrosion is one of the most common and overlooked threats to warehouse racking. Even minor surface rust can reduce the steel’s load-bearing capacity over time.In environments exposed to moisture, chemical vapours, or outdoor weather, corrosion can spread quickly — weakening welds, uprights, and beam connections.
What to do:
Schedule regular inspections and surface treatments. If corrosion is visible on load-bearing members, replacement of the affected sections is critical to maintaining compliance with AS4084-2012/2023 standards.
Bending or Warping:
A Sign of Overload or Impact
Bent beams or distorted uprights are a clear indicator of overloading or forklift impact. Even small bends compromise the structural geometry of your system, creating uneven load distribution and potential collapse hazards.
What to look for:
- Deflection in beams under load
- Uneven spacing or leaning uprights
- Forklift tyre marks or dents on column bases
If any of these are present, stop using the affected bays immediately and arrange for a professional structural assessment.
Loose or Missing Components:
A Hidden Stability Risk
Every bolt, pin, and baseplate in your racking system is designed to perform a critical function. Missing or loose fixings — especially in high-bay systems — can destabilise entire sections.
Common causes include:
- Vibration from forklifts or nearby machinery
- Poor floor anchoring
- Repeated loading and unloading stress
Consistent loosening is a sign of rack movement or fatigue and should be investigated promptly.
Safety Incidents or Near Misses:
Act Before It’s Too Late
If your team has experienced falling product, rack movement, or near-miss events involving forklifts, it’s time to act. Even if damage isn’t immediately visible, impact forces can compromise internal connections and weld integrity.
Immediate steps:
- Isolate the damaged area
- Log the incident for future inspection records
- Book an independent racking audit to assess hidden structural issues
Get a professional inspection immediately — unseen damage can be critical.
Operational Inefficiencies:
Time for a Layout Re-Think
Sometimes the problem isn’t damage — it’s design. If your storage layout no longer matches your workflow or product mix, inefficiencies can create safety risks. Overcrowded aisles, awkward picking zones, or poorly sized bays can all reduce productivity and increase handling hazards.
Modern racking systems can be reconfigured or upgraded to improve accessibility, safety, and compliance — often without replacing the entire installation.
Keep Your Warehouse Safe & Compliant
Routine racking inspections aren’t optional — they’re an essential part of responsible warehouse management. A proactive inspection program reduces risk, extends the life of your system, and ensures compliance with Australian Standards and workplace safety legislation.
At Emrack, we provide:
- Racking inspections and safety audits
- Repairs and component replacement
- System reconfiguration and upgrades
- Certification and load signage to meet compliance standards
Our qualified team ensures your storage systems remain safe, efficient, and fully compliant — with minimal disruption to operations.
Protect Your People.
Protect Your Performance.
Don’t wait for a failure to find the fault. Book your Emrack Racking Inspection today and keep your warehouse safe, productive, and compliant.
