Industrial shelving is designed to support heavy loads and withstand intensive use. However, like all equipment subject to mechanical stress, it can wear out over time. Identifying the signs of wear and tear early on helps to avoid accidents, extend the life of the equipment and maintain a safe working environment.
Here are the main signs of wear to look out for regularly.
1. Visible deformation of the uprights
The uprights (or ladders) are the first elements to be inspected. The most common signs of wear include :
- Twisted or bent uprights
- Shocks at the base of poles, often caused by handling equipment
- Buckling or creasing
- Deformed decks
An upright that is deformed, even slightly, can significantly reduce load capacity and increase the risk of tipping.
2. Corrosion and paint wear
Corrosion is a major indicator of wear, especially in environments that are damp, dusty or subject to temperature variations.
What to look out for:
- Rust stains on uprights or rails
- Chipped or scratchedpaint
- Perforations (extreme but critical case)
Corrosion weakens the metal and can lead to progressive component failure.
3. Sagging or deformed rails
The rails support the pallets directly. Common signs of wear are :
- Banana”twist or deformity
- Visible settlement under load
- Twisted or loose hooks
- Missing or damaged safety pins
A damaged beam must never be reused for heavy loads.
4. Deformation of accessories
Some accessories may also show signs of wear:
- Twisted or cracked gratings
- Damaged pallet stops
- Damaged foot protectors
- Folded spacers for double-depth racks
- Crushed protective clogs
A worn accessory can compromise the stability of the level or structure.
5. Assembly play or instability
On a shelf in good condition, all the rails must :
- Engage firmly in the uprights
- No play
- Be secured by pins in good condition
Excessive gambling can reveal :
- Deformed uprights
- Worn heald claws
- Poor assembly
- Repeated overloading
This type of wear is often a sign that a stall is imminent.
6. Shelving base damaged
The lower area of the shelving is the one that suffers the most impact. Signs of wear include:
- Impact of forklift trucks
- Folds in the plates
- Loose or torn anchors
- Posts crushed over a few centimetres
Any deformation at the base of a rack is critical, as it directly affects its vertical stability.
7. Loose anchors and fixings
Vibration, movement and impact can wear out fasteners:
- Damaged dowels
- Loose bolts
- Cracked anchors in the ground
- Retracted or unstable boards
Racks that are not properly anchored considerably increase the risk of tipping over.
8. Poorly positioned or unstable pallets
This problem is not always directly linked to the shelving, but can be a sign of indirect wear:
- Healds too far apart or sagging
- Slight rack tilt
- Pallets no longer resting on the two beams
Poor pallet support is often the result of a sagging level or poor alignment.
9. Unusual noises or creaking noises
During loading, if you hear :
- Metal creaking
- Recurring clicking noises
- Excessive vibrations
… this may indicate a hidden deformation or incorrect tightening.
Conclusion: regular inspection is essential
The signs of wear and tear on industrial racking are sometimes obvious, sometimes discreet. Regular inspection, combined with good practice (foot protection, driver training, floor maintenance, etc.), will extend the life of your racks and ensure the safety of your entire warehouse.
As soon as a sign of wear is detected, it’s crucial to intervene quickly: replace the component, repair it as required, or carry out a complete overhaul if necessary.