Even the most modern racking system and the best IT systems will not completely eliminate risk if human error occurs. Caring for warehouse space optimization is a natural process in a dynamically growing company. It often happens that, driven by current operational needs, employees or external companies decide to independently modify storage systems—for example, by adding new levels or changing the position of beams. However, a seemingly innocent adjustment can, in reality, drastically reduce the stability and safety of the entire structure.
As a manufacturer of storage systems, we explain why every change in beam configuration, even a minor one, carries serious risk.
1. Drastic reduction in structural load capacity
A warehouse rack is a system operating on the principles of pure mechanics. Every change in level height affects the distribution of forces acting on the structure.
- Upright sensitivity: The load capacity of a vertical column depends directly on the length of the section between bracing points.
- Risk of buckling: Raising the first beam causes the upright to “work” over a longer, unsupported section, making it significantly more susceptible to buckling.
- Scale of danger: Changing the position of a beam by as little as 10-20 cm can reduce the load capacity of the entire module by as much as 30-40%.
2. Hidden deformations and loss of stability
Independent modifications to the rack’s geometry change the distribution of forces and bending moments. Although pallet racks may visually appear stable after a change, processes difficult to notice with the naked eye may be occurring within their structure:
- The appearance of hidden material deformations.
- Excessive vertical deviation of the uprights.
- Increased risk of sudden structural collapse.
- Total loss of stability of the entire rack row.
3. Leverage effect and impact risk
Moving beams to allow for higher pallet storage increases dynamic loads. In the event of a forklift impact, a higher-placed load acts as a larger lever. This increases the risk of compromising the entire system’s geometry, goods sliding off the racks, or the total loss of stability for the entire row. This is one of the most common causes of incidents in warehouses characterized by high inventory turnover.
4. Formal consequences: loss of warranty and standards compliance
Every rack is authorized for operation only in a specific, approved configuration. Unauthorized changes to the level layout mean the system no longer complies with the design. This entails serious legal consequences:
- Loss of the manufacturer’s warranty.
- Non-compliance with key technical standards: PN EN 15635 and PN EN 15512.
- Invalidation of the load capacity plaque (MDO).
- Problems with the insurer: In the event of an accident, insurers rigorously verify whether the structure was modified without the manufacturer’s consent.
5. Safety and workplace ergonomics
An ill-considered change in beam height negatively affects the daily work of personnel. It can lead to the creation of dangerous reaching zones, poorer visibility for forklift operators, and unforeseen changes in forklift driving paths. All these factors increase the risk of injury among employees.
Who can safely modify the racks?
In accordance with safety principles, modifications to racking systems may only be carried out by authorized entities:
- The technical or R&D department of the rack manufacturer.
- Certified service technicians.
- Designers with appropriate authorizations for structural calculations.
After every modification, a re-analysis of the module, an update of the warehouse documentation, and the issuance of new load capacity plaques (MDO) are essential. Remember that changing a beam’s height is a real interference in the structural system which, without professional calculations, can lead to disaster.
Are you planning a reorganization of your warehouse or do you need space optimization? Contact us—as an experienced manufacturer, we will propose safe and standards-compliant structural solutions that meet your operational needs.