Safety in warehouse starts with the right rack design. It is during the design stage that the stability of the entire structure, its compliance with standards, and the minimization of accident risks are determined. As a manufacturer with nearly 20 years of experience in the warehouse systems industry and over 35 years in creating retail shelving, we know perfectly well that a professional design is not an additional cost, but an investment in personnel safety and the continuity of logistical operations.
1. Compliance with standards: the foundation of safety
For a racking system to guarantee the highest level of safety, it must meet strict structural and operational requirements defined by European standards. Properly designed pallet racks are created based on:
- PN-EN 15512 – the standard regulating structural design and static calculations.
- PN-EN 15635 – guidelines defining the principles of use, inspections, and system maintenance.
These standards specify, among other things, permissible deformations, working loads, and the parameters of key components: beams, frames, bracing, and connectors.
2. Structural geometry and system stability
Every detail of a rack has a direct impact on the performance of the entire structure. When creating a design, engineers take into account:
- The height and cross-section of the uprights.
- The length of the beams and support points.
- The placement of vertical and horizontal bracing.
A critically important safety parameter is the height of the first beam. Incorrectly setting this level increases the buckling length of the upright, which directly reduces its load capacity. A difference of just 100-150 mm can reduce the stability of a module by several dozen percent. A professional design eliminates these types of errors.
3. Live loads and warehouse dynamics
The load capacity plaque (MDO) is the final result of complex engineering calculations. Before the appropriate values are placed on it, the R&D department thoroughly analyzes factors such as the mass of the logistic unit, weight distribution across levels, and dynamic loads generated by forklifts. The impact of collisions, pallet micro-displacements, and the use of additional equipment (e.g., bumpers or safety netting) are also taken into account.
Most damage to warehouse infrastructure results from forklift movement. For this reason, the design must include appropriate protection zones along aisles, the use of barriers in areas prone to collisions, and minimum distances between racks and traffic routes.
4. Workplace ergonomics and component compatibility
Structural safety is just as important as the safety of the people working around it. A poor design, even if technically correct, can be ergonomically dangerous and lead to accidents or physical strain. A properly planned warehouse considers:
- Ergonomic reaching zones and optimal heights for order picking.
- Correct aisle widths that ensure adequate visibility for forklift operators.
It is also vital to remember that a rack is a unified system. Mixing components from different manufacturers is extremely dangerous. It leads to a loss of stability for the entire rack row, non-compliance with standards, and the voiding of warranties and manufacturer liability.
5. Long-term operation
Even the best design cannot prevent a disaster if a rack is overloaded, lacks periodic inspections, or is modified without proper calculations. A professional R&D project predefines operational requirements, the frequency of necessary checks, and training instructions for personnel.
A professional rack design is a strict combination of mathematics, technical standards, and years of warehouse practice. An improperly designed system acts like a hidden defect that only reveals itself under load—and usually costs a company far more than the initial investment in a quality project.
If you want to be certain that the structure in your facility is safe, optimal, and compliant with the law, contact us. Our R&D department will prepare a project perfectly tailored to the specific nature of your logistical processes.