How To Reduce the Risk of Falling Items from Pallet Racks

How To Reduce the Risk of Falling Items from Pallet Racks
How To Reduce the Risk of Falling Items from Pallet Racks teaser

16 Aug 2018

Though we’d like to think our warehouse is 100% safe, there are always risks involved when storing inventory on high pallet racks. Sometimes inventory is given a shove by a forklift or truck and racks fall; pallets break; and goods are damaged.

What can go wrong doesn’t necessarily have to go wrong. There are some sure-fire ways to reduce the risk of inventory falling from racks – which could prevent needless injuries or even save lives.

1. Design It Right First

Having a pallet racking system that is designed for easy and safe movement for forklifts or pallet jacks reduces the risk of equipment or vehicles bumping into pallet racks and simultaneously also improves efficiency. The design of the pallet racks should have some safety features built in or added on, such as rack nets and guard panels. Rack nets are fitted to the side of the pallet to help prevent falls. Wire mesh back panels are much like rack nets, but are sturdier, made of steel and are welded in place. The warehouse itself should have adequate lighting – if it doesn’t, it can increase the risk of collisions and incidents.


Pictured: Pallet Racking

2. Proper Pallet Loading

No prevention in the world can help a warehouse from falling objects if the forklift operators are untrained in proper pallet loading. When designing a pallet loading system, the crucial component is the human element. Adequate training of corresponding staff members and forklift drivers is necessary regardless, of their relevant tickets. The proper procedure needs to be followed at all times. Pallets should be centred, even, and given the right allowances of space for your pallet rack. If pallets aren’t shrink-wrapped, make sure they are before loading. Tools such as a forklift-positioning laser can calibrate the fork tines to the pallet, giving the driver a visual guide at all times. Drivers, reps, or visitors should know the capacity of the pallet racks and the procedures at a glance, too.


Pictured: WERKS® Steel Bolt On Cage with Hardwood Pallet

3. Regular Pallet Rack Inspection

Warehouses should conduct regular and thorough pallet rack inspections to make sure there are no rotting or insecure pallets, that frames are sturdy, that beam clips are all accounted for, and there is no hardware around that shouldn’t be there. You and your team should make sure any rack nets and guard panels are still in good shape. If they aren’t, they should be put out of action until all issues are fixed.
A few changes go a long way.

Making some minor changes to the way you work in your warehouse can increase safety not only of your people, but your inventory.
Backsafe offers pallet racking in a range of widths and heights. They are built to Australian Standards and can be dipped in high-vis orange or blue coatings. We can also add steel mesh, which aids to stop item drops and provide frame protection. For more information call us on 1300 305 314 to speak with one of our helpful consultants or send us an email at

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