Modifying pallet racks is a very frequent moment when logistics centers make mistakes that compromise warehouse safety. Changes in product range, seasonal adjustments, or increased turnover force companies to modify their storage layouts and parameters. Unfortunately, many companies treat such tasks as simple organizational chores, completely ignoring standard requirements and technical analysis.
As an experienced manufacturer and advisor, we highlight 8 key mistakes you must watch out for to avoid voiding your technical warranty and putting people, equipment, and goods at risk.
1. Adjusting beams independently without structural calculations
This is by far the most common mistake—treating a change in shelf level as merely unhooking and reattaching beams at a different height. In reality, such a modification:
- Affects the distribution of forces within the rack frame.
- Increases or decreases the load on the uprights.
- Changes the permissible structural deflections and the overall stiffness of the system.
A lack of proper calculations results in overloads and deflections invisible to the naked eye, which can lead to failure or the need for costly component replacement. Every change in high-bay system parameters, no matter how small, requires technical approval.
2. Longer beams and adding new levels
There is a common misconception that using a longer beam automatically means more space for goods. However, one must remember a key principle: a longer beam means lower load capacity. In practice, the load capacity of such a level can drop by several dozen percent. Additionally, adding an extra level without a prior analysis can overload the frames and cause the structure to exceed permissible deformation limits.
3. Removing safety components
It happens that during reorganization, mesh cladding, upright protectors, row spacers, or bracing are dismantled “just for a moment” and then completely forgotten. This is a massive mistake because these elements:
- Protect the entire structure from impacts.
- Ensure the stability of the rack rows.
- Allow for compliance with legal and normative requirements.
The lack of safety features drastically increases the risk of failure, especially in warehouses intensively serviced by forklifts.
4. Anchoring errors after moving racks
Even the slightest relocation of racks requires them to be correctly re-anchored to the floor. The most common oversights in this area include:
- Using old or crumbled mounting holes in the floor.
- Anchoring only selected uprights of the rack frames.
- Choosing anchors with incorrect diameters or lengths.
- Installation in concrete that does not meet the required load-bearing class.
Anchoring according to the manufacturer’s specifications guarantees stability during vibrations and impacts. Every change in location must conclude with a floor verification, proper installation, and a technical acceptance in accordance with the PN-EN 15635 standard.
5. Leaving outdated load signs in place
After modifications are completed, old load capacity plaques (MDO) often remain on the racks, displaying outdated load data. Forklift operators rely on visible information; leaving incorrect signs is the easiest path to dangerous structural overloads.
6. Installing unauthorized accessories
It is also risky to independently install additional gratings, panels, or fire protection systems that were not accounted for by the manufacturer during the design phase. Such “customized” elements cause:
- Overloading of the load-bearing beams.
- Undesirable changes in force distribution within the frame.
- Loss of compliance with current standards.
7. Lack of technical inspection after modifications
In accordance with the PN-EN 15635 standard, any significant change in configuration requires a formal technical acceptance. Skipping this stage means that no one in the facility verifies:
- The correctness of the installation performed.
- Compliance of load capacity with the new assumptions.
- The actual safety of use.
Regular inspections are the indisputable foundation of safe operation.
8. Combining systems from different manufacturers
In older warehouses, “hybrid” configurations built from parts provided by different suppliers are sometimes found. As a rule, such elements cannot be safely combined due to differences in connector geometry, beam and upright profiles, or perforation patterns. Even if they can be physically assembled, such practices violate the PN-EN 15635 standard and carry risks such as a beam dislodging during an impact or a slow, imperceptible loss of load capacity.
Summary
Modifying storage systems is a serious interference with a structure responsible for employee safety and the protection of goods worth millions. Taking independent action—such as self-configured changes, relocation without anchoring, or failing to update load plaques—threatens the stability of entire rows of high-bay racking. To maintain the highest safety standards, every modification must be preceded by a technical consultation and finalized with an official acceptance by the manufacturer.