Pallet Rack Repair with Ease

This week, the Atlantic Installation Team would like to showcase the process and procedures for repairing damaged pallet rack uprights. We have been inspecting and repairing pallet rack since 201o and have been fortunate enough to do so.  The main objective of repairing pallet racks is to restore the structural integrity and functionality of the racking system, ensuring safe and efficient storage and retrieval of goods. Repairing the racks is cost-effective and time-saving. It improves safety and ultimately extends the lifespan of your equipment.

Damaged uprights are a common issue in distribution and storage facilities and typically caused by forklift impacts, general wear and tear, poor maintenance or inspections, and inadequate installation or design. If this occurs in your facility, the repair process offers an economical and simple solution to keep your operation running smoothly with minimal service disruption.

The first step in the process is to take an initial survey of the damaged upright. Accurate measurements and detailed photos in this step are crucial, as they will determine the success of your repair. Ensure that the kit is accurately matched to the rack being repaired, it will need to cover the height of the damage and depth of the upright column. Once this is done, you can order your repair kit. There are several types of kits to order depending on the repair required. They range from bolt-on kits for low-level damage, sleeve and post kits for damaged uprights, adjustable brace kits for replacing damaged or missing struts, and engineered repair kits for a more cust omized solution. Once you decide on the type of repair kit, you can begin the repair process. For this particular walk-through, we will review the process of installing a post kit.

After taking measurements and receiving the appropriate equipment you can begin the repair. To determine the cut height, you can mark an undamaged column of the same type and then take an exact measurement below the hole punch of the undamaged column. After that, you can transfer the measurement to the damaged upright column. Use a square to mark the cut line on all sides of the post. Before placing the jack into position, it may be helpful to cut the face of the upright to mark exactly where you will be cutting through.

Once the cutlines are properly marked, it’s time to install the lifting jack. Before proceeding, inspect the jack to ensure it is in good condition and not leaking hydraulic fluid under pressure. Place the lifting head on the post at the same point where the braces are attached. Fasten the lifting head to the upright column and pressurize the jack. Remove the anchors from the damaged column with the existing anchor at or below floor level, and then loosen the fastener on the anchor of the undamaged column. Pressurize the jack to lift the column 1/8 of an inch and cut the horizontal and diagonal braces close to the inside of the damaged column. Once this is complete, cut the entire damaged column and remove it. Place the repair kit into position and insert horizontal and diagonal braces inside the rear opening of the repair kit. It is crucial at this step to ensure that the kit and the horizontal braces are plumb and level with the rest of the structure, and that the diagonal braces are in their original, undamaged position. Once finished, release a small amount of pressure on the lifting jack to seat the repair kit to the frame, and use the provided clamps and hardware to bolt the kit to the frame. Tighten the anchors on the undamaged frame to appropriately secure the newly installed repair kit, and clean the worksite as needed.

Even though you now have the instructions to guide you through pallet rack repair, sometimes it’s better to leave it to the professionals.  Don’t hesitate to contact us by phone or through our contact form if you need help with repairs in your facility.

Tags: #palletrack, #palletrackrepair, #rackrepair

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