Pallet Racking Structural Integrity Scan Checklist

Visually inspect uprights for straightness. Are there any visible bends or deflections exceeding 1/4 inch over 10 feet? (Red if yes)

Inspect uprights for forklift impact damage, especially at the base. Are there any dents, scrapes, or deformations? (Amber if minor, Red if significant)

Verify base plates are securely anchored to the floor. Are any anchors missing, loose, or damaged? (Red if any)

Are column protectors installed and in good condition, especially in high-traffic areas? (Amber if damaged or missing)

Inspect welds on upright frames for cracks or breaks. Are any welds compromised? (Red if yes)

Check for rust or corrosion on uprights, especially near the floor. Is there significant corrosion weakening the structure? (Amber if surface rust, Red if structural)

Verify uprights are plumb using a level. Are uprights out of plumb by more than 1/2 inch over 10 feet? (Amber if yes)

If uprights are spliced, inspect splice connections for proper bolting and alignment. Are any bolts missing or loose? (Red if any)

Confirm load capacity signs are present and legible on each upright frame. Is the information accurate and visible? (Amber if missing or illegible)

Visually inspect cross beams for straightness. Are there any visible bends or deflections exceeding 1/4 inch over the beam length? (Red if yes)

Inspect cross beams for forklift impact damage. Are there any dents, scrapes, or deformations? (Amber if minor, Red if significant)

Verify beam connectors are properly engaged with the upright frames. Are connectors fully seated and secure? (Red if any are disengaged)

Confirm safety pins are installed in all beam connectors. Are any safety pins missing or damaged? (Red if any are missing)

Inspect welds on beam connectors for cracks or breaks. Are any welds compromised? (Red if yes)

Check for rust or corrosion on beams, especially at connection points. Is there significant corrosion weakening the structure? (Amber if surface rust, Red if structural)

Inspect beams for signs of overloading (excessive deflection). Is there evidence of overloading beyond the stated capacity? (Red if yes)

Confirm load capacity signs are present and legible for each beam level. Is the information accurate and visible? (Amber if missing or illegible)

Verify that beam locking devices (e.g., clips, bolts) are correctly installed and functioning. Are any missing or damaged? (Red if any)

Observe load placement on pallets. Are loads evenly distributed and stable? (Amber if uneven or unstable)

Inspect pallets for damage (broken boards, missing supports). Are pallets in good condition to support the load? (Amber if damaged)

Ensure loads do not protrude beyond the pallet edges excessively. Is there excessive overhang that could cause instability? (Amber if yes)

Verify load weights do not exceed the rack's load capacity. Are load weights within the specified limits? (Red if exceeded)

Ensure stacking heights are within safe limits and do not compromise stability. Are stacks too high or unstable? (Red if yes)

Verify adequate aisle clearance for forklift operation. Are aisles free from obstructions? (Amber if obstructed)

Observe if loads are properly secured (e.g., shrink-wrapped, strapped) to prevent shifting. Are loads adequately secured? (Amber if not secured)

Assess if mixed pallet types are used and if they are compatible with the racking system. Are incompatible pallets being used? (Amber if yes)

Verify forklift operators are properly trained and certified. Are operator certifications current? (Red if not certified)

Observe forklift operators adhering to posted speed limits within the warehouse. Are operators exceeding speed limits? (Amber if yes)

Assess the effectiveness of pedestrian walkways and barriers to separate forklifts from foot traffic. Are pedestrian walkways clearly marked and used? (Amber if not clear or not used)

Observe forklift operators using the horn at intersections and blind spots. Are operators using the horn appropriately? (Amber if not used)

Verify forklifts are regularly maintained and inspected. Are maintenance records up-to-date? (Amber if not up-to-date)

Observe forklift operators handling loads safely and avoiding abrupt movements. Are operators handling loads smoothly and carefully? (Amber if not careful)

Verify forklift operators are wearing seatbelts. Are operators wearing seatbelts? (Red if not wearing)

Ensure adequate lighting is provided in areas where forklifts operate. Is lighting sufficient for safe operation? (Amber if inadequate)

Confirm that there is a system in place for reporting forklift incidents and near misses. Is there a clear reporting process? (Amber if not clear)