Cold storage facilities play a critical role in industries such as food, pharmaceuticals, and chemicals—but the extreme environments in which they operate introduce unique structural and operational risks for pallet racking systems.
Low temperatures, condensation, ice buildup, and high forklift traffic can accelerate damage, increase corrosion, and reduce a rack’s tolerance to impact. When rack failures occur in cold storage, the consequences can be severe, putting employees, inventory, and operational continuity at risk.
Why Cold Storage Rack Safety Requires a Different Approach
The global warehousing and storage services market is expected to grow at a compound annual growth rate (CAGR) of 6.17% from 2025 to 2033, driven in part by increasing demand for refrigerated storage, making effective strategies for managing cold storage rack safety more critical than ever.
These environments are designed to maintain extremely low temperatures, making it essential to safeguard both workers and the integrity of stored goods. A key element of cold storage operations is the racking system, which must be carefully managed to ensure safety, efficiency, and longevity. Regular maintenance and thoughtful material selection are critical to preventing safety risks and supporting the long-term performance of these systems.
In this article, we outline the best practices for cold storage rack safety to help cold storage facilities operate safely, efficiently, and with confidence, even in the most extreme environments.
1. Conduct Regular Internal Inspections and Maintenance
Figure 1. Safety inspector assessing pallet racks
Routine internal inspections are the first line of defense against potential accidents. Cold storage facilities can be harsh on equipment due to low temperatures, humidity, and constant forklift traffic.
Over time, racking in cold storage may exhibit signs of wear and tear, including deformation, component damage, and, more commonly in cold environments, rust and corrosion. These issues can compromise the structural integrity of the racking system and increase safety risks.
Actionable Steps:
- Perform regular internal rack inspections — on a daily, weekly, and/or monthly basis as recommended by the Rack Manufacturers Institute (RMI).
- Look for signs of rust, corrosion, wear, or any damage to the racking systems or deteriorated pallets.
- Ensure that all anchors and bolts are correctly tightened, and that safety pins are installed at each beam connection point.
- Consider hiring certified rack inspectors to conduct in-depth evaluations and ensure the racking system complies with safety standards.
2. Ensure Proper Load Distribution and Visible Load Capacity Labels
Figure 2. Load capacity label for rack systems
An overloaded or improperly loaded rack can cause serious accidents, including rack collapses. Cold storage areas often require the stacking of heavy products, so racks must be built to handle the intended load. Ensuring even load distribution is crucial to maintaining rack stability and preventing excessive strain on the structure.
Actionable Steps:
- Follow the manufacturer’s guidelines regarding weight limits and load distribution.
- Avoid stacking products in a way that creates uneven pressure on certain parts of the racks.
- Remove any ice buildup and minimize the source (i.e., any moisture or water sources/leaks contributing to ice formation).
- Ensure each system is certified by engineers or manufacturers, and that all systems display clear, visible maximum load capacities.
3. Implement Proper Employee Training and Attire
Figure 3. Best practices for cold storage (RMI, 2024)
Employee training is essential to maintaining a safe cold storage environment. Workers must understand how to safely navigate aisles, load and unload materials, and recognize rack-related hazards that are more prevalent in cold storage, such as reduced visibility, icy floors, and increased impact risk to pallet racking.
Additionally, employees must be adequately equipped to work in low-temperature environments, wearing appropriate clothing and gear to prevent cold-related injuries, such as frostbite.
Actionable Steps:
- Conduct regular safety training sessions that focus on rack safety, proper load handling, and emergency procedures.
- Include training on using cold storage-specific equipment, including forklifts and pallet jacks.
- Create a clear emergency response plan in case a rack collapses or another incident occurs.
- Ensure that workers are dressed correctly for the cold, with clothing that is adequately warm for the temperatures, and that their attire is not damaged or ripped, as it can affect both safety and comfort in the cold storage environment.
4. Monitor Temperature and Humidity Levels
Figure 4. Corroded rack columns
Extreme cold temperatures and fluctuating humidity levels can put additional stress on pallet racking systems. For example, condensation can form in humid environments, leading to rust and corrosion on steel components. At the same time, extremely cold temperatures can increase material brittleness and reduce a rack’s tolerance to impact damage.
Actionable Steps:
- Monitor temperature and humidity levels continuously within the cold storage facility to ensure they remain within optimal ranges.
- Ensure that racks and other storage components are designed to withstand both the cold and any associated moisture.
- Regularly check for ice buildup or excessive condensation on racks and structures, which can lead to dangerous conditions.
- Opt for galvanized steel components for your racking system to reduce the risk of rust and corrosion in cold environments. Galvanized materials are specifically designed to withstand harsh conditions, making them an ideal choice for cold storage applications.
5. Plan for Emergency Situations
Figure 6. Emergency warehouse planning
Despite all safety measures, accidents can still happen. In the United States, reported cases of injuries and illnesses in warehousing operations nearly doubled between 2016 and 2021, increasing from approximately 42,500 to 80,500 cases.
Cold storage environments pose additional challenges for emergency response, including icy conditions and the potential freezing of fire suppression systems. Planning for emergencies in advance is essential for protecting employees, inventory, and facility operations.
Actionable Steps:
- Develop a comprehensive emergency response plan that covers evacuation procedures, first aid, and cold storage-specific hazards, and review it regularly.
- Ensure that fire suppression systems are regularly tested to confirm proper operation in cold storage environments.
- Post current emergency contact information, evacuation routes, and hazard identification signage in visible locations throughout the facility.
Conclusion: Building Safer and More Resilient Cold Storage Operations
Cold storage racking systems are essential to the safe and efficient operation of any cold storage facility, but the extreme conditions they operate in leave little margin for error. Without proper inspection, load management, training, and environmental controls, minor issues can quickly escalate into serious safety risks. By following best practices for cold storage rack safety and addressing problems early, facilities can significantly reduce the likelihood of accidents while protecting employees, inventory, and uptime.
A proactive approach to managing cold storage rack safety not only improves worker protection—it also supports operational efficiency, compliance, and long-term asset performance. In demanding cold storage environments, prevention is always more effective and less costly than reacting to failures after they occur.
How Damotech Supports Cold Storage Rack Safety
Damotech helps cold storage facilities take control of rack safety through specialized engineering inspections, load capacity certifications, engineered rack repair solutions, and protective products designed to perform in harsh environments. Whether you operate a single cold storage warehouse or manage multiple sites, working with rack safety specialists can help you reduce risk, maintain compliance, and extend the life of your racking systems.
Talk to a Damotech rack safety expert to assess your cold storage racking systems and build a safer, more resilient operation.
References
Banerjee, A. (2024, 12 20). Warehousing and Storage Services Market Size, Share & Trends Analysis Report By Type (General Warehousing and Storage, Refrigerated Warehousing and Storage, Farm Product Warehousing and Storage), By Ownership (Private Warehouses, Public Warehouses, Bonded). [https://straitsresearch.com/report/warehousing-and-storage-services-market]
Hantz, C. R. (2023). COVID-19: OSHA NEEDS TO DO MORE TO ADDRESS HIGH INJURY RATES OF WAREHOUSE WORKERS. U.S. Department of Labor. [https://www.oig.dol.gov/public/reports/oa/2023/19-23-013-10-105.pdf]
RMIwriter. (2024, 08 10). Designing Pallet Rack Systems For Refrigerated Coolers: Best Practices. [https://www.rmiracksafety.org/2024/08/10/designing-pallet-rack-systems-for-refrigerated-coolers-best-practices]
Frequently Asked Questions About Cold Storage Rack Safety
Why do pallet racking systems in cold storage require special safety considerations?
Cold storage environments expose pallet racking systems to low temperatures, condensation, ice buildup, and high forklift traffic. These conditions can accelerate damage, increase corrosion, and reduce a rack’s tolerance to impact, increasing the risk of structural failure if not adequately managed.
How often should we inspect racking in cold storage facilities?
Regular internal inspections should be performed on a routine basis, such as daily, weekly, and/or monthly, as recommended by the Rack Manufacturers Institute (RMI). These inspections help identify issues like corrosion, deformation, missing safety components, or damaged pallets before they become serious safety risks.
What types of damage are most common in cold storage racking systems?
Common issues include deformation, component damage, rust, and corrosion caused by moisture and condensation, and damage resulting from forklift impacts. Ice buildup and humidity can further contribute to deterioration over time.
Why is load distribution critical in cold storage warehouses?
Cold storage facilities often store dense, heavy products. Improper load distribution or overloading can place excessive strain on racks, leading to collapses. Ice buildup can also add unintended weight, making even properly designed systems unsafe if loads are not carefully managed.
What role do load capacity labels play in rack safety?
Clear and visible load capacity labels help ensure racks are loaded within their approved limits. Each racking system should be certified by engineers or manufacturers and display its maximum load capacities, allowing employees to load racks safely and consistently.
How does employee training contribute to rack safety in cold storage?
Proper training helps employees safely navigate aisles, operate forklifts and pallet jacks, handle loads correctly, and recognize hazards related to racking. Cold storage environments can reduce visibility and increase the risk of impact, making training essential for preventing rack damage and accidents.
How do temperature and humidity affect pallet racking systems?
Fluctuating humidity can cause condensation, leading to rust and corrosion, while extremely low temperatures can increase material brittleness and reduce impact resistance. Monitoring environmental conditions and checking for ice or condensation helps mitigate these risks.
Why is emergency planning important for cold storage facilities?
Even with preventive measures, accidents can still occur. Cold storage environments present challenges, including icy conditions and potential issues with fire suppression systems. Emergency planning helps protect employees, inventory, and facility operations in the event of an incident.
