Published: July 2025
In today’s fast-paced warehouse environments, the relationship between forklifts and racking systems is more critical than many operators realize. Racking manufacturers design their systems to withstand specific types of loads, impacts, and movements—but often, the real-world usage of these systems stretches beyond those expectations. The result? Avoidable damage, increased risk of injury, and costly repairs.
For forklift trainers and warehouse supervisors, understanding the key concerns of racking companies is essential to creating a culture of safe navigation. Doing so not only extends the life of racking equipment but also improves operational efficiency and workforce safety.
Racking structures may look robust, but they're engineered for precise tolerances. Contrary to popular belief, racking is not meant to endure constant or even occasional collisions. Even low-speed impacts can compromise the structural integrity of uprights and beams, which can lead to collapse over time.
According to the Rack Manufacturers Institute (RMI), most rack damage is caused by human-operated forklifts, and minor impacts can still require inspection and replacement (MHI RMI).
What forklift operators should know:
Improperly placed pallets can push the limits of a racking system. Placing loads too far from beam centers, off-center, or unevenly distributed adds unnecessary strain on beams and connectors. Over time, this can warp horizontal components and weaken the rack’s load-bearing capacity.
Tips trainers should reinforce:
Racking companies frequently report that speed and limited visibility are leading causes of rack-related incidents. Operators working under pressure or navigating tight aisles without clear line of sight are more likely to strike racking—often without realizing the damage they’ve done.
Best practices:
The Occupational Safety and Health Administration (OSHA) recommends a minimum aisle width of at least 3 feet wider than the widest equipment to be operated (OSHA).
Sometimes, shortcuts become habits—like using a forklift to nudge or realign pallet positions, or stacking beyond posted rack capacities. These behaviors can seriously undermine the safety of the entire racking structure.
Why this matters:
Recommendations:
Between 2002 and 2023, OSHA investigated 20 workplace accidents relating to rack collapses– all of which resulted in fatalities or hospitalized injuries. Here are three of those investigations:
July 2023: An employee was driving a forklift through a dry materials warehouse when he noticed a load-bearing horizontal beam on a rack had come loose. When he attempted to investigate, the rack collapsed and pinned him against the forklift. Investigation 1684221.015.
December 2020: An employee was operating a turret truck inside an industrial freezer. A second employee was taking inventory near the industrial freezer, when the turret truck struck the racking inside the freezer, causing the rack to collapse and the pallets to fall. The operator was hospitalized while the second employee did not survive from the traumatic impacts. Investigation 1506467.015.
March 2018: An employee was operating a stand-up forklift while retrieving material from a cantilever storage rack. The employee backed into another storage rack and it fell. He suffered fatal blunt force trauma. Investigation 1304647.015
Many racking-related failures could be prevented if early signs of damage were caught and addressed. But often, operators don’t know what to look for or aren’t encouraged to report minor dings and scrapes.
What trainers and supervisors can do:
According to RMI guidelines, any rack that has been hit should be considered damaged until evaluated by a qualified professional (RMI Rack Safety).
Warehouses that value racking safety tend to see fewer injuries, reduced maintenance costs, and better productivity. It begins with mindset: viewing the racking system as an integral, fragile part of the workspace—not background hardware.
Steps to take:
Ultimately, when forklift operators understand the "why" behind safe navigation, they become more invested in protecting the space around them.
Q: How often should racks be inspected for damage?
A: Visual inspections should happen weekly. Any rack that has been struck should be assessed immediately by a qualified person.
Q: Can a forklift operator fix a damaged rack?
A: No. Repairs should only be done by trained professionals following the racking manufacturer’s guidelines.
Q: What should I do if I notice slight rack damage but it doesn’t look serious?
A: Report it immediately. Small bends or tears can grow worse over time and lead to failure.
Q: Are there tools to help operators navigate more safely around racking?
A: Yes. Technologies like aisle cameras, proximity sensors, and floor markings can improve awareness and reduce accidents.
Q: Do pallet types or sizes matter when placing loads?
A: Absolutely. Using standardized pallets helps distribute weight evenly and prevents racking strain.
Safe forklift navigation isn’t just about avoiding people—it’s about respecting the structure of the warehouse itself. Racking systems are engineered to perform well within specific conditions. When forklift operators understand those limits, everyone wins: fewer breakdowns, fewer injuries, and fewer costly surprises. Trainers and supervisors are in the best position to connect those dots and build a warehouse culture that prioritizes both precision and prevention.
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