by James Averitt, on Nov 6, 2023 12:20:50 PM
253,100 injuries and illnesses were reported in the transportation and warehousing sector by the U.S. Bureau of Labor and Statistics in 2021. That marked a 22% increase from the previous year. As accidents are on the rise in the warehouse industry, OSHA is taking a harder look at compliance industry-wide. Their increased vigilance extends to your pallet racking. However, the lack of specificity in OSHA pallet racking standards makes compliance challenging for most businesses. In this article, we'll identify the 4 most common ways to avoid pallet rack citations, as well as how to ensure you have the correct load limits for your racks.
OSHA Pallet Racking Standards
Pallet rack violations are a common citation during OSHA inspections. However, OSHA has few specific regulations for warehouse racking. Instead, they include most pallet racking standards within the general safety clause, which mandates that employers must provide a workplace free of recognized hazards. This lack of enumerated requirements can make compliance frustrating. However, violations can be avoided by following a few pallet rack safety protocols.
- Proper installation. All pallet racking should be properly installed. When pallet racking is incorrectly installed, it’s at greater risk of collapse due to instability and thus creates a recognized hazard to employees.
- Damage-free racking. It's easy for a forklift or other moving equipment to accidentally clip the corner of a rack during routine work. However, collisions like this cause damage to the racking that impairs their load capacity. This creates a collapse risk. Racks should be inspected regularly, and when dents are found, the rack should be unloaded until it can be repaired. Also, consider rack protection products to reduce the chance of damage.
- Manufacturer-approved modifications. Only manufacturer-approved repairs or other modifications should be made to pallet racking. Non-engineered modifications can impact the stability of the rack. This is dangerous to employees working in the area and qualifies as an OSHA violation.
- Posted capacities. Different pallet rack configurations have different load limits. Due to the variability in capacity, racks must be labeled so workers do not accidentally overload the rack. Among other requirements, the maximum load for each bay should be clearly visible on the label.
Pallet Racking Weight Limits
Pallet rack load limits vary depending on the manufacturer and model. As such, weight limits are often one of the least understood aspects of compliance. OSHA sets no specific standards for pallet rack capacity. Instead, they refer to the regulations the American National Standards Institute (ANSI) set in standard MH16.1-2023. These ANSI racking standards lay out how pallet racks should be designed, tested, and used. Ultimately, these standards address four vital areas that need to be understood when determining pallet rack load limits.
Beam Length
Pallet rack beam dimensions are either described by beam width or beam length. This is somewhat misleading as both terms refer to the same dimension: the horizontal size of the beam.
To determine the beam length you will need to first decide how many pallets it will support side by side. Next, collect the dimensions of the pallets stored. Then, multiply the width of a single pallet by the number of pallets stored. Finally, add 6 inches per pallet to that number to account for the additional space required by fire code.
For example, if you use standard 40-inch by 48-inch pallets and store two side by side, you'll multiply 40 inches by 2 for 80 inches. Then, add 12 inches for a total beam length of 92 inches.
Beam Capacity
Beam loading limits are described as capacity per pallet load pair. To determine the maximum weight your beam will need to support, set the maximum weight of each pallet you plan to store on the rack and multiply that by the number of pallets stored on the beam.
So, if you were planning to store pallets that each weighed 1,000 lbs, you would need a beam with a capacity of at least 2,000 lbs per pair.
Manufacturer capacity charts are a great tool to determine what capacity your rack beams can support based on beam length. These charts are invaluable when deciding which beam fits your space and the requirements of your products.
Upright Capacity
The third factor in determining pallet rack load limits is the rated capacity of the uprights. Collectively, rack uprights must be able to support the weight of each tier to which they are connected. For example, if our hypothetical pallet rack from above will have four tiers, the four uprights that make up the four corners of the rack must be able to support at least 8,000 lbs. If we increase that to 5 tiers, the uprights must now support 10,000 lbs. Additionally, if the upright will support beams on more than one side, it must be rated to handle the weight of the tiers on all sides.
Load Labels
Correct labeling is vital because of the variability in pallet racking weight limits. In fact, this is one of the most commonly cited pallet racking violations. The ANSI standard for storage racks states that racking systems must be identified with one or more load placards that contain the following information:
- Maximum permissible unit load and/or maximum uniformly distributed load per level
- Average unit load
- Total average load per bay
- Maximum total load per bay
These labels must be displayed on or near the rack system in a clearly visible spot. Additionally, anytime modifications are made to the rack, the load limits must be reassessed, and the plaque must be updated. While the standard does not include an exact number of labels that must appear per rack, labeling each bay individually is a best practice.
Make OSHA Compliance Easy
There's a lot to cover when it comes to OSHA compliance, and these are only the basics. So, don't try to go it alone. Instead, let us help. Our expert team provides on-site pallet rack assessments to ensure your racking is properly loaded. We'll determine your racking's rated capacity and even supply you with the necessary placards and labeling stickers. If an issue is found during your visit, our team can help find a solution to get you back into compliance fast. To learn more or sign up for your on-site assessment, contact us online or visit one of our locations throughout Georgia and Florida.
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Further Reading
7 Pallet Rack Safety Tips for Warehouse Managers Who Want Fewer Accidents
How Can I Protect My Pallet Racking?
Is It Okay To Mix Racking Materials From Different Manufacturers?
