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Pallet Racking Inspection Checklist: What to Consider?

Pallet Racking Inspection

Pallet racking systems are made up of heavy-duty and industrial-grade durable materials but, like any other storage system, they are also vulnerable to accidental forklift strikes and susceptible to damage. Pallet racks are specially designed to withhold heavy weights and strain of the heaviest loads in your warehouse. It becomes crucial to go for a timely warehouse-racking inspection as minor damage or irregularity can cause a complete racking collapse resulting in a complete shutdown.

To prevent major safety risks and operational setbacks, it is important to have timely and regular pallet racking inspections in place. When it is known what, how, and when to check, the warehouse leaders can efficiently secure the place and environment at large. The warehouse pallet racking solution works at an optimum capacity once all the safety measures are in line.

Pallet Racking Inspection Checklist

Today, we’re sharing a step-by-step guide to pallet rack inspection that can assist you to comply with safety regulations and promote a more productive workforce. Care to learn more? Let’s get started.


  • Inspect the uprights from front to back. Check for vertical alignment and ensure uprights are straight and not leaning.
  • If you find scrapped paint, that’s a sign of corrosion and that needs to be fixed at the earliest to ensure worker’s safety.
  • Check for signs of damage, such as cracks, splits, or bending for the column protectors as well.
  • Verify that base plates are securely anchored to the floor.


  • Check for any visible signs of damage, such as dents, twists, dings, or cracks as the beams can also suffer damage caused by forklifts or other equipment.
  • Ensure beams are correctly seated in the connectors. Take immediate action if any sign of damage or broken weld is found.
  • Confirm that safety clips are tight in place to prevent accidental dislodgement.
  • Before moving further, check the deflection levels when the racks are empty.


  • Proper documentation is the backbone of a good pallet racking inspection. Review inspection records and maintenance logs and ensure they are properly maintained.
  • Verify that any previous issues or recommendations have been addressed.
  • Documentation is essential for maintaining a record of the condition of the system, tracking any issues or repairs, and ensuring compliance with safety regulations.
  • Important points to document include the date of inspection, location, inspector’s name, specific findings and recommendations, action taken for the damages, and proper approval.

General Inspection:

  • Check whether the racks are leveled. This level should be maintained as the ones that are out of alignment are damaged and load should be reduced for such racks.
  • Check for signs of damage, such as dents, bends, or twisted components.
  • Look for rust or corrosion, especially at joints and connection points as those places are at a higher risk of damage.
  • Ensure all bolts, nuts, and fasteners are securely tightened.

·      Confirm that load beams are level and evenly spaced. Make sure the racks are not overloaded as these sturdy structures also have limits that can decline as a result of routine wear and tear.

  • Check weight capacities at regular intervals of time and ensure they are not exceeded.
  • Inspect diagonal bracing for any signs of damage or deformation. Ensure that the bracing is securely attached to the uprights and beams.
  • Verify that there is adequate clearance between the top of the pallet and any overhead obstructions. Ensure aisles are clear and free from obstructions.

Other Important Points

Signage and Markings: Check for clear and visible signage indicating load capacities, safety instructions, and potential hazards. Ensure aisle markings are clearly visible.

Employee Training: Confirm that employees are trained in safe pallet racking practices and ensure they understand how to recognize and report any issues.

Emergency Procedures: Ensure employees are familiar with emergency procedures in case of a pallet racking failure or collapse. Depending on the specific type of racking system (e.g., drive-in, push-back), conduct additional checks as needed.


Regular inspections should be conducted by trained personnel at least annually, with more frequent inspections recommended for high-traffic areas or where there is a higher risk of damage. Make sure the inspection conducted is in line with warehouse racking regulations of the concerned area. Contact Gold Coast Racking for an elaborate information on Pallet Racking and its features. 

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