How to Avoid Common Pallet Racking Mistakes Warehouses Make

Pallet racking is one of the most efficient ways to organise warehouse space, but even small design or maintenance errors can lead to reduced efficiency, safety issues, or expensive repairs. Whether you are setting up a new storage system or maintaining an existing one, understanding what not to do is just as important as knowing best practices.

1. Overloading Racking Bays

One of the most frequent and dangerous errors is exceeding the load capacity of your racking system. It can be tempting to maximise every inch of space, but overloading can cause beam deflection, frame damage and, in the worst cases, a full racking collapse.

How to avoid it: Always check the manufacturer’s load notices and adhere to maximum weight limits per beam level. Make sure each pallet is evenly distributed across the beams, and train staff to identify early signs of beam stress such as bending or distortion.

2. Poor Warehouse Layout and Access

Even if your racking is structurally sound, a poorly planned layout can cause operational bottlenecks. Narrow aisles, blocked access, or poorly placed end-of-aisle racking can slow picking times and increase the risk of forklift collisions.

How to avoid it: Plan your racking layout around workflow, taking into account traffic routes, turning circles and storage frequency. Allow sufficient clearance for forklifts and pallet trucks, and review your layout annually as stock types and volumes change.

Learn more about How to Choose the Right Pallet Racking for Your Warehouse Layout

3. Skipping Regular Inspections

Pallet racking is not a fit-and-forget system. Daily wear, forklift bumps and shifting loads can all affect its stability over time. Skipping inspections can mean missing minor issues before they become major and expensive problems.

How to avoid it: Schedule weekly visual checks by warehouse staff and annual inspections by a SEMA-approved racking inspector. Record and report all damage immediately. Replace damaged uprights or beams rather than attempting on-site repairs.

4. Ignoring Floor Level and Ground Conditions

Even the best racking system can fail if it is built on uneven or unstable flooring. Poor ground conditions can lead to uneven load distribution, leaning frames and instability over time.

How to avoid it: Ensure the warehouse floor is level and strong enough to support both the racking and stored loads. Conduct a site survey before installation, and use baseplates and shims to correct minor level variations.

5. Inadequate Staff Training

Human error is one of the leading causes of racking damage. Forklift operators who are unaware of load capacities or safe handling procedures can cause collisions, uneven loading and long-term structural wear.

How to avoid it: Provide racking-specific training for all warehouse operatives. Clearly display load signage and safety notices, and encourage staff to report damage immediately.

6. Choosing the Wrong Racking Type for Your Needs

Not all pallet racking is created equal. Selecting the wrong system, such as using standard wide aisle racking where narrow aisle or drive-in racking would be better, can waste space or reduce productivity.

How to avoid it: Assess your stock turnover, pallet sizes and picking methods before selecting a system. Consult a storage specialist to match your operational needs with the right racking design. Combine racking types where appropriate, such as drive-in for bulk storage and adjustable pallet racking for mixed inventory.

7. Neglecting Safety Accessories and Protection

Corner guards, end barriers, and upright protectors are inexpensive compared to the cost of repairing a collapsed bay. Skipping these accessories can leave your system vulnerable to forklift impact or everyday wear.

How to avoid: Install upright and corner protectors in high-traffic zones. Use rack end barriers to protect aisle ends from impact, and regularly inspect all safety accessories for damage or looseness.

Avoiding Mistakes Starts with Expert Design and Ongoing Care

At Storage Concepts, we have been designing and installing pallet racking systems for over 40 years. Our experienced team ensures your racking is built to SEMA standards, fully compliant with UK regulations, and optimised for your warehouse operations.

If you are unsure whether your existing system is compliant or need advice on upgrading, our team can carry out a full racking inspection and layout review.

Learn more about our Pallet Racking solutions for warehouses.

Common Pallet Racking Mistakes (and How to Avoid Them)