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.
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.
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.
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.
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.
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.
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.
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.
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]