A typical pallet rack frame structure includes braces, columns, beams, and baseplates, all working together to support the load. The overall integrity of the racking system depends on the strength of its components, particularly the often-overlooked pallet racking bracing. These diagonal or horizontal members are bolted or welded between frame columns in specific patterns.
While they may seem small and insignificant, rack braces play a crucial role in maintaining the stability and safety of racking systems. In this blog, we’ll explore how to keep your braces, ensure your racks are in optimal condition, and create a safer, more efficient warehouse.
The uprights are responsible for transferring the weight of the goods to the ground, providing vertical strength. They also support the downforce of the system’s weight and the inventory on the shelves. However, if these uprights deviate from their ideal position, it can result in severe consequences. The braces (sometimes referred to as struts or pallet racking bracing) are precisely engineered to provide rigidity to keep the system from moving side-to-side or forward-to-back. Braces are designed to keep the frame posts in perfect plumb.
Braces provide rigidity to the frame structure by inhibiting it from moving laterally. They are key engineering components that can prevent a catastrophic warehouse collapse, a domino effect of frames failing. This domino effect is seen in many of the warehouse collapse videos that are available online. Pallet racking bracing, therefore, are mission-critical to your racking system’s functional integrity.
The original pattern for your racking should be maintained as per your original Load Application and Rack Configuration drawings (LARCs). If one of your brace patterns looks different from the rest, this could indicate damage or unauthorized modifications.
Braces are vulnerable components in your racking system that can be easily damaged. Most braces are made of lighter gauge steel than the uprights and are in conspicuous locations. These factors make them easily prone to impact damage from forklifts, pallets, and products. Additionally, less visual factors like environmental factors and improper loading can also slowly damage braces. However, knowing what causes damage is half the battle. Here are the major factors to watch out for that cause damage.
Corrosion is a metal’s worst enemy and diminishes its strength and structural integrity. Like every metallic component, braces (or struts) are also prone to damage from environmental factors like moisture and chemicals. Corrosion is more likely to occur in harsh industrial environments with plenty of exposure to chemicals and water. If your business operates under such conditions, inspect corrosion damage more often than usual. Your inspections should look for severe rust and the beginnings of rust where the paint has failed. Be sure not to dismiss rust as merely surface level. There can be more damage inside of the pallet racking bracing that is not visible outside. Qualified inspectors can quantify the damage more precisely.
Damage due to forklift impacts is one of the most common causes of damage to a pallet racking system. Most of the racking system collapses also result from forklift strikes. Even if the forklift impact initially damages other system components, the same impact forklift can also damage and weaken the braces. Pallet and inventory strikes could also damage braces and their structural integrity. To counter this problem:
Bolting is a common method of attaching different system components. However, these bolts might loosen with time. Take care of loose or missing bolts immediately. If they’re left unattended, the system’s ability to carry loads and prevent frame failure degrades. The brace’s ability to provide structural integrity or flexural rigidity to the upright frames is highly dependent on proper connection to the columns.
Be sure to check for any missing pallet racking bracing within the warehouse system. Perhaps one of the frames was not installed properly, and one of the braces was left out. Additionally, maybe the brace was damaged and removed carelessly. Or perhaps the brace was damaged and fell off the frame. It is important to scan each frame to make sure that all the required braces are present. Typically, braces will conform to the same pattern throughout your warehouse. If it is out of the standard pattern, a brace is likely missing.
Racking frames with horizontal and diagonal pallet racking bracing are the common optimum solution for most pallet racking systems. These patterns and frequencies were explicitly designed by the original engineer of your racking system for your specific warehouse use pattern. When frames are missing engineer-designed diagonal braces, they create an open panel. Open panels are generally defined as no diagonal brace between two horizontal pallet racking bracing.
Diagonal braces significantly increase the directional rigidity of frames, which horizontals cannot do alone. Moreover, they are also responsible for ensuring down-aisle stability. Avoid open panels. If you have an open panel in your racking system frames, this is likely due to damage or removal of a component that is not part of the original engineering. Take note of all open panels, consult your original as-built plans, and look for brace repair kits.
Although braces improve the protection against damage from irregular loads, they don’t make the system utterly immune to it. Uneven distribution of the load on the racks might exceed the tolerance of your pallet racking bracing. All loading should conform with the racking load capacity placards or labels. Always stay within the load distribution designations for each bay. Always load your system according to engineering directions. Failure to do this can overload the braces and cause racking failure.
Warehouse pallet rack inspections should always be done by a trained professional. Damotech trained technicians can perform these official inspections. However, at times, an initial observation needs to be made by a non-trained inspector. Damotech has an online inspection checklist and printed inspection guides for this purpose. If you see any damage in your preliminary review of your racking system, contact us immediately to schedule a FREE damage assessment to diagnose and repair your pallet racks. In most cases, a single point of damage doesn’t result in system failure, but collective failure may occur when accumulated unrepaired damage points are combined. Therefore, it is important to inspect any damage and take immediate action.
Deflection, deformation, and sheared steel
Missing parts or fasteners or open panels
Rust and corrosion
Check regularly for signs of corrosion and rust. Even slight corrosion should be addressed before leading to a more significant issue. If corrosion is present, take the necessary repair measures to remedy the problems, including replacing the components. Galvanized components can be used to mitigate rust and corrosion.
Look for lost or missing fasteners and connecting components. Professional help is highly recommended to deal with such issues. Also, report any open panels.
If the entire frame is out of plumb by more than 1/2" in 10 ft in either plane, there might be an issue with your braces as well.
Upon impacts by forklifts, pallets, and other equipment, an immediate preliminary inspection must be done to ensure no damage has occurred. Routine inspection should also look for unreported impact damage from forklifts, pallets, or products.
Repairing your pallet rack brace instead of replacing it can save significant time and money while maintaining the integrity of your racking system. A repair allows you to address damage without the downtime associated with a complete replacement. Plus, repairs are often quicker and cost-effective, mainly when conducted by professionals who can reinforce the structure with minimal disruption to your operations. Regular inspections can identify issues early, allowing for repairs before a collapse occurs and ensuring safety and efficiency in your warehouse.
Trained technicians should always do repairs that maintain the original engineering specifications of your racking systems. All damaged or missing braces should be replaced with parts that are identical or stronger (engineering-approved).
Damotech has engineered pallet rack repair kits to repair the upright frame components and damaged braces. We have many engineered designs and endless custom solutions that work with any racking type, brand, or punch style. In addition, we engineer all our parts according to ANSI/RMI 16.1 standards. Those standards state that all parts must meet or exceed original engineering specifications and should be inspected and installed by a trained professional.
Contact Damotech to schedule a free rack repair assessment or ask a question. We are committed to the safety and efficiency of your pallet racking systems in your warehouse.
Another great alternative to replacing your entire frame is our DAMO BRACE. Engineered with high-strength structural steel tubing, it repairs damaged pallet racking bracing and works with all brands and types of racking. Its innovative design makes installation fast, allowing you to strengthen your racking system without tearing down the entire structure.
Installing Damo Brace saves you the cost of replacement and enhances the safety and longevity of your racking system with minimal downtime. It can be adapted to lengths between 24" and 94" and can be used for horizontal and diagonal configurations. It can be installed by warehouse staff, and you can even keep a supply of Damo Braces on hand for quick repairs.