How to Level Pallet Racking?

Pallets stored on uneven racks are always at risk of falling off. Along with accidental inventory loss, an uneven pallet racking system is a constant threat to every warehouse employee’s safety. That’s why leveling your pallet racking system after its installation is crucial. In this guide, we’ll tell you how to level pallet racking and what steps should be taken to maintain it. But first, let’s take a quick look at what causes an uneven pallet racking system.

Causes of Uneven Pallet Racking

Several factors can cause a pallet racking to become uneven. Some of these happen over time and are unavoidable. However, a few major factors can easily be avoided with precautions. 

For instance, uneven warehouse floors and improper installation are two major causes of uneven pallet racking systems. But, with due diligence and proper inspection beforehand, these factors can be avoided. 

Other factors include:

• Overloading: Exceeding the load capacity can result in bent or damaged beams which can disrupt the leveling of the entire pallet racking system. It’s best to follow the load capacity chart and stay below the load capacity of your pallet racking system.

• Uneven Weight Distribution: Uneven weight distribution for prolonged periods will eventually result in permanent bends in the structure. 

• Forklift Accidents: Day-to-day forklift collisions can cause serious structural damage to a pallet racking system over time. Upright protectors and racking frame barriers can help safeguard your pallet racking structure against forklift collisions.

Importance of Pallet Racking Leveling

A level and plumb racking structure is important for several reasons. However, some major factors highlight the importance of a level and even pallet racking system.

• Safety: If the racking system is uneven, there’s always a risk of pallets loaded with heavy inventory falling off the racking system, causing serious injuries to the employees and resulting in inventory loss.

• Prolong The Lifespan of Your Racking System: A properly level pallet racking system evenly distributes the load of all pallets stored. This minimizes the strain on the uprights and beams of your pallet racking system and prolongs the life of each component and the entire system.

Now that you know the importance of an even pallet racking system, let’s move on to our guide on how to level pallet racks.

Step-by-Step Guide to Level Pallet Racking

Re-leveling an uneven pallet racking system requires a systematic approach. Before you can level the pallet racking, you first need to have the right tools, pin down the uneven spots, and then apply the changes needed. 

Gather the following tools before you start trying to level your pallet racking system:

• Laser/Carpenter’s Level: To check the vertical and horizontal alignments.

• Measurement Tape: For accurate measurements of different pallet racking dimensions.

• Wrenches & Socket Sets: To make necessary adjustments to bolts.

• Anchoring Tools: To use as needed during the adjustments.

• Shims: To plumb the upright frames.

Once you have these tools ready, make sure you unload the entire pallet racking structure before starting the step-by-step process.

Step 1 – Check the Warehouse Floor

Before you start examining the pallet racking system, thoroughly inspect the warehouse floor for sloping, cracking, or any other damage. Even if the warehouse floor was in perfect condition when you installed the pallet racking system, regular forklift traffic and inventory load could cause damage.

Step 2 – Check the Horizontal & Vertical Level

Use a laser level or a carpenter’s level to check horizontal and vertical alignments of your pallet racking beams and uprights. Laser levels are more accurate out of the two. If you find any irregularities/misalignments, it’s best to adjust them instantly. 

You’ll need to check and adjust all the connections for horizontal misalignments. If any components are severely damaged, replacing them would be the best choice. 

On the other hand, resolving vertical misalignment is a bit more tricky as you have to install shims under the baseplates. Shims are tiny plates of varying sizes, usually made out of metal. These are used to get rid of any vertical misalignments in the upright frames.

Step 3 – Recheck the Alignments & Tighten the Bolts

Once you think the pallet racking is plumb, recheck both vertical and horizontal alignments with a laser level. Make any final adjustments needed and tighten the bolts to secure the changes. One important thing to remember when performing this final step is to not over-tighten the bolts and screws. This can cause warping in the frame and all your hard work goes to waste.

How To Maintain Pallet Racking Level?

Over time, every pallet racking system can become uneven due to factors like floor settling or forklift collisions. However, with regular maintenance, you can keep your pallet racking level and plumb.

• Regular Floor Inspections: Keep an eye on your warehouse floor, especially around the baseplates. If there are any signs of floor settling or shifting, you must adjust the baseplates using shims. Regular pallet racking inspections are also necessary.

• Ensure Even Load Distribution: Uneven load distribution and overloading cause misalignment in major components of a pallet racking system. You want to follow the load capacity charts and make sure the entire inventory load is evenly distributed throughout the system.

Conclusion

A level pallet racking system is important for secure pallet storage and a safe warehouse environment. Luckily, now you know how to level a pallet racking. By following our step-by-step guide, you can re-align your pallet racking system and maintain it plumb. 

FAQs

1. How Often Should I Check the Level of my Pallet Racking System?

You should check the level of your pallet racking system once every 6 months. However, if you notice any visible signs of instability, it’s best to instantly inspect the floor and the entire racking structure and resolve any underlying issues.