Interview Featuring Charles Carbonneau, Ph.D., Chief Engineer
A pallet rack collapse takes seconds. The aftermath — injured workers, an OSHA investigation, weeks of disrupted operations, a possible citation — takes years. Many serious rack failures are preceded by visible warning signs that a trained rack safety professional can often identify during a warehouse walk-through and confirm through inspection, documentation review, or engineering analysis.
Charles Carbonneau is Damotech’s Chief Engineer and has inspected racking systems across hundreds of North American distribution centers. We sat down with him to talk about what a real pallet rack safety program looks like, what OSHA actually requires (and doesn’t), how often racks should be inspected, and the warning signs most warehouse managers walk past every day without noticing.
KEY TAKEAWAYS
- OSHA does not specify a pallet rack inspection frequency, but 29 CFR 1910.176 requires storage conditions that do not create hazards, and the General Duty Clause may apply to recognized serious hazards.
- RMI guidance and industry best practice support at least annual rack inspections by a qualified rack professional, supplemented by more frequent internal visual checks in high-traffic or higher-risk areas.
- A real pallet rack safety program is a continuous cycle — Damotech calls this the Rack Safety Flywheel — connecting inspection → insight & prioritization → repair or replacement → protection → employee training → documentation → re-inspection.
- Many serious rack-related incidents can be reduced or prevented by identifying visible damage, unsafe loading, missing documentation, and recurring impact zones early and correcting them through a documented rack safety program.
Meet Charles Carbonneau, Damotech’s Chief Engineer
Starting with my first job, I’ve contributed to the development and design of software used for the calculation of all kinds of structures: steel, concrete, or wood, while respecting North American design codes and accounting for seismic effects.
What led you to specialize in the field of warehouse racking?
In the 2000s, a client approached my team to adapt our software to the specifics of pallet racking calculation. Subsequently, during warehouse visits, I often noticed how neglected these structures were, despite the considerable loads they were bearing. From then on, I became interested in the safety of pallet racks as a focus, and the “training - inspection - certification” adventure began.
Since you’ve joined Damotech, its team of engineers has grown significantly. What is the role of the engineer who works at Damotech?
Our engineers travel across North America to perform pallet rack inspections in warehouses and distribution centers. They produce compliance reports in accordance with local design codes. They keep themselves in good shape by walking row upon row of racks and documenting what they see! Their mandates generally involve taking measurements and photos of the racks and issues, and sometimes calculating the load capacities for operators who have lost track of their configuration drawings (LARCs) or who have made modifications to the systems and want to ensure their compliance. Several of our engineers also provide on-site training on best practices for recognizing hazards and methods of preventing damage to pallet racks.
What are their responsibilities?
The engineer is responsible for producing accurate, precise reports that fulfill his professional responsibilities and guide the warehouse manager in corrective actions that help keep pallet racks safe over time. They must be rigorous and very observant.
Why is pallet rack safety important?
I’ve visited many warehouses, and each time I make a point of observing how safety is approached there. I once saw a beautiful wall with photos of family members with a sign that said: “This Is Why We Work Safe.” This example, for me, says it all. It’s frustrating to learn that an accident could have been avoided, which is unfortunately the case with a vast majority of warehouse accidents.
What happens when a pallet rack collapses?
We are talking about accidents that can have serious consequences. As a warehouse manager, imagine hearing the crashing sound of a pallet rack, followed by the tremor of a domino-effect collapse. Imagine having to count your employees to determine whether a team member is confined somewhere. Think of the time and effort required to try to free them from such a mess. Not to mention dealing with the aftermath of such an event.
Of course, there are these extreme cases, but what about a warehouse that is not exposed to such an event?
Warehousing is becoming increasingly competitive. Serving customers means storing and delivering orders quickly and systematically at a low cost. To achieve this, it’s necessary to optimize storage space and the velocity of the pallets. All the pallet positions must be usable, even profitable. To achieve this, you need a pallet rack safety and maintenance program.
What are the steps of a pallet rack safety program?
We’re talking about having a plan that will ensure the preservation and proper functioning of your storage systems. Safety in this area involves checking the load capacity of the racks, performing regular inspections of the systems, identifying and repairing damage, and protecting places at risk of being hit. I see the program as a continuous cycle, not just a one-time inspection.
What does this kind of initiative entail, and who should implement it?
A company and its managers have a responsibility to their workers: they must provide a safe workplace. I wrote a blog post about it. If the company has a health and safety team, they must work together on this. Next, you need to know the condition of your pallet racking, and this involves doing a baseline survey, a complete inspection, if you will, of the rack systems. After reading the resulting report, measures are put in place to correct the situation and improve the safety of the pallet racks.
What should you do after a pallet rack inspection?
Each warehouse is unique. Some begin by offering training on pallet racking safety to make their workers aware of the issues surrounding the racks. You can get the opinion of an inspector or engineer on the condition of the pallet racks and their load capacity. I advise customers to proceed with repairs or replacements at the indicated priority locations immediately after the inspection. Don’t wait. Then begin a maintenance and inspection cycle to prevent future damage.
How often should we have our racks inspected?
We recommend an (annual) inspection by an independent third party, followed by regular reviews by well-trained employees. In aisles that are used daily, a weekly or daily check may be necessary. Beyond inspections, a process should be put in place for workers to report issues as soon as they are observed. This article shares examples of when you might want to get your racks inspected.
Does OSHA specify a pallet rack inspection frequency?
No, because frequency depends on several factors specific to each warehouse. We are often asked this question. Here are some examples of factors:
- What types of storage systems are we talking about: conventional pallets, drive-in, push back, pallet flow?
- What is the nature of the operations?
- Is it storage, or is it a place with heavy forklift traffic?
- What are the loading methods?
- Are the operators well-trained?
- Are there guarding products in place?
If you haven’t had your racks evaluated by a qualified rack professional in the last 12 months, schedule a consultation with the Damotech engineering team. We’ll review your facility, your storage profile, and your risk exposure, and tell you where to start. Schedule your next inspection.
Meet the Engineer Featured in This Interview
Charles Carbonneau, Ph.D., P.Eng., is a structural engineer with more than 20 years of experience in structural dynamics. As Chief Engineer at Damotech, he leads the engineering services team and was instrumental in developing the Rack Safety Platform.
Before joining Damotech, Charles was Technical Director at Graitec Canada (formerly CivilDesign), the company behind Advance Design America — an advanced structural analysis and design platform used to engineer buildings, towers, racking systems, and bridges in steel, concrete, and wood.
Across his career, Charles has trained warehouse teams, inspected racking systems in distribution centers throughout North America, and built engineering tools used by structural engineers worldwide. He is recognized for the depth of his technical knowledge, his rigor, and his commitment to mentoring the next generation of rack safety engineers.
Connect with Charles on LinkedIn · See all articles by Charles
Frequently Asked Questions About Pallet Rack Safety
How often should pallet racks be inspected?
What happens when a pallet rack collapses?
Does OSHA require pallet rack inspections?
What are the steps of a pallet rack safety program?
What should you do after a pallet rack inspection?
Why is pallet rack safety important?
Who is responsible for pallet rack safety in a warehouse?
What is a LARC and why does my warehouse need one?
