Pallet Rack Beams: Critical details that prevent beam failure

Pallet rack beams are the heavy lifters in your pallet racking system. Valuable inventory rests on these mission-critical parts in your warehouse. Yet, there are some small details that, if neglected, could cause these parts to fail. This article will reveal best practices regarding beams that every warehouse manager should know to keep your warehouse functioning safely and running efficiently.

How Critical are Pallet Rack Beams?

There are three essential facts about pallet rack beams, the most prominent being that they hold the weight of your inventory between the upright frames of your pallet rack system. Yet, there are two less obvious things beams do that are often overlooked.

First, they provide horizontal rigidity to the racking system. This keeps the system from swaying left to right. The second and least apparent is how they impact the torque strength of the frame. The pallet rack beams provide rigidity to the frame’s columns, keeping them from bending under the weight lower in the frame structure (illustration below). Keeping your beams functioning optimally is critical to your entire warehouse. Keep reading to make sure you cover all the details and best practices that prevent beam failure.

Correct Installation of Pallet Rack Beams

Proper Pallet Rack Beam Spacing

Pallet rack beams should be specified by an engineer familiar with the design and the construction of pallet racking. If the size of your inventory and beam requirements change, an engineer must be consulted and may, upon analysis, be able to specify different vertical spacing for your system. Any alterations in spacing patterns should only be done by an engineer as these spatial gaps affect the overall load capacity of your frame. Larger gaps will cause frame columns to torque away from the gap due to the lack of horizontal rigidity that larger gaps create. Never casually change the beam spacing, follow the original design of your racking system, and remember to contact an engineering expert prior to changing the original “as built” design.

Proper Pallet Racking Beam Clip Engagement

The pallet racking beam clip or engagement pin system used by the OEM manufacturer should be used to connect your beam to the columns unless an alternate engineered connection has been approved for use. Inspect the beam clip or pin to ensure it is fully and properly engaged. Often, on roll form frames, there is a safety clip or device that is used in addition to the standard engagement clip or pins to ensure that the beam to frame connection does not disengage accidentally. RMI states, “Hold-Down Devices (Beam Locks)” – Beam locks are required by the RMI Specifications to prevent pallet rack beams from accidental dislodgement caused by fork truck activity in the rack position below. These can be bolts or pins, hooks, or other devices that satisfy the RMI specified 1000-pound uplift requirement. Make sure each beam endplate is fully aligned and properly engaged with the upright columns. Disengaged pins or clips can lead to pallet rack beams failing and cascading damage to facility personnel or other racking structures. Additionally, don’t assume that a bigger bolt is better than the original clips. The beam engagement clips or pins were specifically engineered for your rack, even engineered to fail under specific conditions to keep the entire system safe. Never use an aftermarket bolt to replace a missing pin or safety clip that has not been approved by a qualified engineer. These small parts can make or break the safe operation of your whole warehouse. Tons of weight is supported by these small but mighty connectors. It is mission-critical that you assure their proper fit and proper condition.

Proper Loading and Labeling

Each pallet rack beam has a maximum weight that has been designated by your pallet rack system engineer. Pallet rack beams should be labeled with the maximum weight capacity and the label should be on the front of the beam facing the aisle. It is recommended by RMI that system load capacity rating charts should be displayed in conspicuous locations at the end of each row displaying the maximum allowable load for each beam configuration in that aisle. Loads must be evenly distributed and balanced as well. Typically your loading software, if you use this technology, should provide you with a pattern that will even your load. If you do not have this functionality, a visual inspection of the location of inventory can tell you if the loading is even. Even loading should be a uniform distribution from left to right, with OSHA recommendations of the heavier pallet loads on the bottom beam locations rather than on the top.

Proper Decking

When decking is present it should be installed properly. Some applications do not require decking. Wireframe or even wooden decking can be used. Verify that the decking meets the engineering needs and local codes of your specific inventory type and pallet type. Consult an engineer prior to choosing or installing a decking system. Additionally, pallet sizes should conform to the recommended sizes of your original engineering of the system. When decking or pallets fail, inventory can shift or fall, damaging your racking system with the potential of injuring facility personnel. This is yet another critical detail to be aware of to assure the safe, efficient functioning of your warehouse.

Pallet Rack Beam Types

Pallet Rack Beam Shapes

There are three typical beam shapes: box beam, step beam, and c-channel beam. Box beams have no inside step slot, and wire deck, if used, is clipped on top of these bars. Step beams have a step that is used as a slot for crossbars and wire decks. The original beam shape, as per your original engineering specifications, must be retained, or the beam will not maintain the original design capacity. Do not risk compromising safety. Damaged pallet rack beams must be replaced immediately.

Pallet Rack Beam Length

There are different lengths of pallet rack beams. Pallet rack beam length needs to be long enough to accommodate pallets with typically an additional 8” per pallet, 4” to the left and right of the pallet, leaving 8” between the pallets. As the length of the beam increases, so does the gauge of the beam. If not, the beam capacity will be significantly reduced compared to a shorter length beam. The total weight is calculated by your system engineer, and it is critical not to exceed these standards.

Pallet Rack Beam Size

The type of steel and the thickness used in your pallet rack cross beams will also affect its ability to support weight. Since steel weights and gauge are not obvious by observation, make sure that you always use the specifications given to you stated on the original engineering plans. Never replace beams with “less expensive” substitutes providing less or inferior steel to save money. (RMI recommends that you should not mix pallet rack beams from different manufacturers.) Be sure that all replacements or new beams meet your original engineering specifications.

Damage to Pallet Rack Beams

Forklift Damage

Damage to your pallet rack beams can come from several sources. The most common are:

• Forklifts and loading vehicles
• Impacts can damage pallet rack beams and deform or disengage the locking clips or endplates. Severe dents or shearing of the beams can also take place. Often when the loading vehicle is too large for the aisle width, damage can occur more frequently.
• Damage can be done to the bay being loaded and also bays behind the loading bay that are backed into by forklifts. Make sure you are using the proper material handling equipment for your racking system design, operated by trained professionals. Have drivers report any and all impact incidents.

Improper Loading

Damage from overloading is a common form of damage in this category. This can cause deformation (bending) of the beam. While slight deformation is acceptable, it can become dangerous when the deformation from excess weight exceeds the maximum allowable. This deformation can be measured. See more about inspection and deformation standards below.

Unauthorized Modifications

Some warehouse staff don’t understand the importance of the precise location of pallet rack beams as a qualified engineer would. For example, you may work in the building, but it doesn’t mean you understand the architectural design. They think that the modular pins used on racking mean that beams can be moved to new locations without any issues. Sometimes beams are even removed to accommodate traffic or larger inventory. These modifications change the torque forces in your frame and can lead to failure of your frames. This is damage to your system that doesn’t show up in bends and dents but is damage to the original engineering design that leads to a weakness just as unclipped beams or a damaged beam would. Take care to train your staff to never move a beam without proper consultation by a qualified engineer.

Seismic Events

Earthquakes can twist and torque your racking system. After these events, damage may occur to endplates and locking pins, and the column pinholes. From a safety perspective, be proactive, and be sure to schedule a thorough professional inspection following a seismic event as soon as possible.

Corrosion

Corrosion is most dangerous in the small pins and clips that hold pallet rack beams in place. The load of your system depends on these small parts not disintegrating with rust or corrosion. The beams themselves can also rust through in exposed conditions. Special attention should be given to the very lowest section of the upright frame. Corrosion can affect the welds that connect the footplate to the upright frame post. If beams are mounted just above the floor, special attention should be given to the welds that connect the beam to the endplate and the endplate to the frame. Be aware that corrosion may not be easily spotted from the front.

Upright Damage

Pallet rack beams depend on a sound connection to the upright. Uprights can be damaged when twisted during attachment or removal, impact, or seismic event. Both uprights and pallet rack beams must be taken into account when repairing. A trained professional from Mac Rak can guide you through the complexities of this process to make sure that these components have been properly inspected and conform to all engineering standards.

Inspection Techniques

Once your racking system has been installed properly, regular inspections should be taking place to ensure that there is no severe damage to your racking system. Full inspections should take place by a professional at regularly scheduled intervals and be documented for reference. Your racking inspection logs can used in the event of an OSHA inspection.

Informal inspections

Informal and ongoing inspections should be performed by you and your team. Workers should be empowered to spot damage and report issues. Mac Rak’s online inspection tool can be used for these informal inspections. Our online tool is free and works on any cell phone or tablet and is a great reference tool for you and your staff to informally spot damage or safety concerns. It requires no downloading. It is available on our website at macrak.com/inspection. Training your staff to recognize and report damage helps keep warehouses safe. Informal inspections should never replace formal inspections by trained professionals according to RMI standards. Mac Rak has free safety inspection posters that can be displayed in your facility to educate your warehouse personnel on how to identify and report damage racking. These posters are free and can be requested on this page.

Formal Inspections

RMI standards dictate that formal inspections of pallet racks should be performed routinely, depending on the loads and use patterns of your pallet rack system. Mac Rak has qualified trained inspectors that can perform these inspections for you. Don’t delay. Call Mac Rak today to schedule your inspection at (815)723-7400.

Informal Pallet Rack Beam Inspection Checklist

Look for all of the damage listed below. Take note and document the specific location, if any of these conditions exist:

• Bent or downward deflection. Report deflection if the deflection distance is greater than the length of the span divided by 180.
• Missing, disengaged, or corroded beam clips.
• Load Labels missing or unreadable.
• Beam end plates disengaged from the frame, bent, or weld failures.
• Dents, cuts, and cracks, if any, are seen in pallet rack beams or endplates.
• Improper loading that doesn’t conform to the load standards of your racking system.
• Missing pallet rack beams: beams that have been moved or removed for whatever reason.
• Pro Tip: check behind beam connectors, Check front and rear beams, unload if necessary to inspect. Use a lift to inspect higher points. Report all temporary repairs.

Pallet Rack Beam Repair

Beam Repair

Typically pallet rack beams should not be repaired. They should be replaced by identical OEM parts specified on the original engineering plan. Minor issues with locking pins and connectors may be addressed in a manner that conforms to the specified repair methods from the manufacturer or qualified engineer, which can be performed by the manufacturer or a trained technician. The beam should be offloaded when the damage is detected and inventory moved. Severe damage may affect the entire frame. An experienced, trained inspector from Mac Rak or a qualified engineer will be able to inform you about what will be required for repair or replacement.

Upright Repair

The repair of uprights often directly interacts with your pallet rack beams. Upright repairs affect beams in two ways. First, beam damage can also damage the uprights. The punch holes on beams can be sheared, bent, or twisted. Never reinstall a beam into a damaged upright. Always repair upright prior to reinstalling your beams. An experienced inspector can detect any damage done to your upright columns. Mac Rak has technicians that can install engineered Mac Rak upright column repair kits on your damaged upright frames that will restore your columns faster and more efficiently than OEM replacement frames. Mac Rak can accomplish this with our broad selection of pallet rack repair parts for the base of your racks, where most of your damage will occur. Mac Rak also manufactures an intermediate repair for damage higher up in your rack frame. Secondly, often damage to the upright takes place right above or below a beam. As a result, the upright column section where the beam is attached to the upright needs to be replaced. If the beam attachment to the repair part is done without engineering oversight, the engineering integrity of the entire designed system will be compromised. Mac Rak repair parts and installation professionals never modify OEM beams. All Mac Rak pallet rack repair parts are fully compatible with all brands and types of pallet rack beams and conform to all engineering requirements.

Watch out for beam repairs where endplates are removed.

One reason Mac Rak should be your preferred inspector and repair partner is that we never cut the beam and plate off performing what is commonly referred to as a “hook over” endplate repair. Some manufacturers of repair kits will cut off the endplates of the OEM beams and then bolt the beam to a bracket or some other device to support the beam. This completely changes the engineering and the whole dynamic weight interactions of your frames in ways in which your pallet rack system was not designed. Mac Rak will never compromise the integrity of your original engineering of the OEM beams, endplates, and connection pins without engineering approval and consultation. Mac Rak upright repairs are compatible with all types of punches and styles and will equal or surpass your current system engineering. Our repairs work with the critical engineering of your beams and your entire racking system.

Details of Beam End Plate Engineering Matters

Note: Through many years of experience installing systems that were designed by Interlake and installed in both seismic and non-seismic locations, there were four different beam welds used to fasten the beam to the endplate depending on the seismic requirements for the area the rack system was being installed. Interlake typically used an “A” weld that was their most common weld for all pallet rack beams. They had a “B”, “C” and “D” weld beam that was used commonly in seismic conditions. Each one of these welds, “A” through “D” welded more of the beam to the endplate as the letters increased. The “A” weld typically welded the vertical front and back of the beam to the endplate. The “B” & “C” weld added additional welding on the top and bottom of the beam to the endplate connection. The “D” welded the entire beam vertically and horizontally, including the step of the beam to the endplate.

Cutting an endplate off and attaching it to a device such as a “hook over” negates the engineered design, structural integrity compromises the strength of the entire system because one or two bolts bolting a roll form endplate to a bracket is not seismically compliant with the design of the seismic system. Don’t be fooled by false claims that a hook over can replace the original design integrity and capacity of the OEM design beam to endplate connection. It can’t!

Mac Rak innovated and pioneered the beam-to-repair-kit connections that do not remove the OEM end plate that has been engineered, tested, approved, and used for more than 20 years.

ANSI standards for pallet racking systems and beams.

The American National Standards Institute (ANSI) has set up specific rules and regulations for the usage of industrial components. Pallet racking systems are also included in these rules. Here are the rules directly associated with pallet racking systems and beams.

According to ANSI MH16.1:

• “The racking system operator is responsible for maintenance and repair of the storage systems,” i.e., the person in charge of the pallet racking system is to be held responsible for any misconduct in the process.
• “Upon visible damage, the pertinent portions of the rack shall be unloaded immediately and removed from service by the user until the damaged portion is repaired or replaced,” i.e., when you inspect a component to be damaged or broken, you immediately unload the damaged section of racking and tag it out of service until the damage is repaired or replaced. You’re not allowed to use the system until the damaged component has been replaced/repaired and reinstalled into the system.
• “Any beam with visible deformation or cracking of the beam end connectors should be unloaded and replaced. Be sure beams are fully engaged and installed with proper safety locks.”, i.e., when you detect visible deformation in the beams or notice cracking, you need to immediately remove the load and replace the damaged component. You can utilize the system after repairing the component and engaging it in the system.
• There’s a safe deflection limit that you must adhere to when handling beams. The maximum allowed deflection can be calculated by dividing the length of the beam by 180.

These regulations apply to all types of pallet racking systems, irrespective of the kind of steel (cold-formed or hot-rolled). Moreover, these rules are applicable to movable as well as non-movable racking systems.

Key Takeaways

• Install your pallet racks properly according to the manufacturer’s guidelines.
• Inspect beams informally and formally regularly
• Use Mac Rak to inspect and install all engineered parts so as to avoid improper repairs that may compromise the design and the engineered capacity of the system.
• Beams are a key component of any safe and efficient warehouse system.
• Contact Mac Rak if you have any questions or need help with keeping your personnel and warehouse safe and efficient. (815) 723 – 7400