The Dangers of Adjustable Pallet Racking & how to avoid them
Adjustable Pallet Racking (APR) systems are an essential storage solution for warehouses, enabling efficient organization and direct access to goods. However, when improperly installed, overloaded, or neglected, these systems can pose serious safety risks. On the other hand, when used correctly, APR systems provide a versatile and durable solution that helps businesses thrive. Let’s explore the dangers of Adjustable Pallet Racking and the steps you can take to minimize these risks.
The Dangers of Improper Use
Structural Failures
- Overloading beams beyond their rated capacity can cause them to buckle or collapse, risking injury and product loss.
- Misaligned or improperly installed components weaken the system’s structural integrity.
Impact Damage
- Forklift impacts can damage uprights and frames, compromising the rack’s ability to bear loads safely.
- Unprotected corners and frames are particularly vulnerable.
Falling Pallets
- Without proper backstops or protection meshes, pallets can fall, causing serious harm to workers below.
- Poorly placed or unbalanced loads increase the risk of goods shifting or falling.
Neglected Inspections and Maintenance
- Rust, loose bolts, and damaged components can accumulate over time if inspections are not carried out regularly.
- Failure to identify these issues can result in sudden and catastrophic system failures.

Steps to Minimize Risks
1. Follow Installation Guidelines
- Ensure the system is installed by trained professionals who understand the manufacturer’s specifications.
- Use the correct type of system, such as APR for Class 400 (conventional racking) or Class 300 (VNA), based on your storage needs.
2. Train Personnel
- Train employees on safe loading and unloading practices, including weight limits and pallet placement.
- SESS specialized training courses provide valuable insight on the inspection of pallet racking to help reduce risk in the workplace.
- Educate forklift operators on navigating safely around racking systems to avoid impacts.
3. Inspect Regularly
- Conduct regular inspections of all racking components, including beams, uprights, and connectors.
- Check for damage, wear, or corrosion. Rely on our expert inspections for 35+ years of safety experience and peace of mind.
4. Install Safety Features
- Use upright protectors, corner protectors, and frame protectors to guard against forklift damage.
- Install pallet backstops, protection meshes, and load beams to prevent pallets from falling.
- Incorporate load notices to clearly display weight limits and system guidelines. SESS can provide load notices tailored to your system.
5. Avoid Overloading
- Always adhere to the load capacities specified by the manufacturer.
- Use accessories like support bars or container supports for non-standard loads.
6. Perform Routine Maintenance
- Tighten loose bolts, replace damaged parts, and address rust or corrosion promptly.
- Maintain a record of inspections and repairs to track the system’s condition over time.
- A Person Responsible for Racking Safety should perform visual checks each week
Why Choose Professional Inspection Services?
While in-house checks are crucial, partnering with professional inspectors like SESS ensures your APR system complies with all safety standards, including BS EN 15635:2008 and FEM recommendations. Professionals can identify hidden vulnerabilities and recommend tailored solutions, providing peace of mind and minimizing operational risks.
Conclusion
Adjustable Pallet Racking systems are invaluable for efficient storage when used responsibly. However, improper use, lack of maintenance, and neglecting safety features can lead to hazardous conditions, endangering both workers and inventory. By following best practices, investing in safety features, and scheduling regular inspections, businesses can enjoy the full benefits of APR systems while protecting their workforce and operations.
Contact SESS today to schedule a professional inspection and secure your storage system’s safety and efficiency!