Pallet rack safety inspection checklist

Stop-now conditions

If you find any of these, unload the affected bay before repairing — not after.

• Visibly bent or twisted upright column, front or side
• Bent, buckled, or detached diagonal or horizontal brace
• Cracked welds at any brace or footplate connection
• Cracked, bent, or lifting footplate; missing or pulled anchors
• Beam with permanent sag that remains after the load is removed
• Beam connector with torn clip holes, or a beam missing its safety clip

Monthly walk checklist

• Load capacity plaques posted, legible, and matching the current beam configuration
• Safety clips or pins present on every beam connection
• Wire decking in place, seated, and undamaged; no missing pallet supports
• End-of-aisle and upright protection present where lift traffic passes
• Pallets in good condition and correctly seated on beams, not overhanging
• Nothing stored in flue spaces; sprinkler clearances maintained
• Aisles clear, floor free of debris, anchors tight
• Damage log reviewed and open items assigned a repair date

Build the reporting habit

Inspections only work if operators report strikes without fear of blame. Pair the walk with a no-penalty impact-reporting rule and a visible damage log at the dock — it surfaces problems weeks earlier than a scheduled inspection alone.

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