Pallet Rack Safety Pins: Extra Security in a Tiny Package

Posted on November 24, 2023
Alexander Jones, CEP

What is a Safety Pin?

When you think of a safety pin, the first thing that may come to mind is a pin commonly used for securing clothing material together or for earrings. A safety pin in pallet racking has a similar role of acting as extra security. Whether you refer to them as racking safety pins, locking pins, beam locking devices, safety clips, or j-pins, their purpose is to secure pallet rack beams to uprights, preventing the beam from disconnecting when struck with an upward force caused by a pallet load or forklift.

The Need for Safety Pins

Static pallet racking systems commonly allow loads of 2500 lb per pallet. That is 5000 lb for a pair of beams, roughly equivalent to supporting a pickup truck! You may find it surprising that many racking designs have beams hooked directly into columns. They are held solely by gravity and the weight of the supported load pushing down on them, with nothing else preventing the beam from being lifted out of place. With this design, beams can be quickly removed by lifting them up and out, making them easy to assemble and disassemble.

Two safety pins securing the beams into the column

Figure 1. An example of two safety pins securing the beams into the column.

Consider the scenario where a beam is accidentally lifted while the level underneath it is loaded or unloaded. Lifting equipment can raise a pallet and its load with enough force to also lift the beam above it, something that can be difficult for an operator to notice. Suppose the lifted beam disconnects from the supporting column. In that case, it is then at risk of falling when the lift operator backs away, dropping the supported product and potentially causing damage or injury. Another critical factor is that installed beams contribute to the racking capacity by laterally supporting the columns from buckling. Therefore, removing beams - intentionally or not - reduces the rack's load capacity, which could then be overloaded due to its new configuration. For this reason, a rack’s load capacity should be re-evaluated whenever beams are reconfigured (moved, removed, or added).

Pallet racking pins are important because they prevent beams from unclipping from the supporting rack upright when subject to a lifting force that may occur in normal warehouse operations.

How Do Safety Pins Work?

Safety pins are installed at the connection between the beam and the column. Every beam is supported on each end; therefore, two pins per beam need to be installed. Each safety pin must be capable of resisting an upward force of 1000 lb (4.5kN) as specified in design codes CSA A344 Section 11.3.1 and ANSI MH16.1 Section 5.4.2.

Steel storage racks using structural steel members with bolt-on beams do not fall under the considerations of these articles. Beams that are securely bolted to the columns do not have the same risk of disconnecting as clip-on beams. Inspecting the bolts to verify they are present and properly tightened to the installation specification (torque) is important for these racking types.

How to Prevent Dislodging of Beams

Most commonly, beams are dislodged due to unintentional contact when using lift trucks, both when loading or unloading pallets or by collisions. To reduce the risk of damaging the racking, pallets should only be loaded into cells where clearance of 6in can be maintained between the top of the load and the next beam above it (RMI Considerations for the Planning and Use of Industrial Steel Storage Racks 2.13.2). Additionally, aisles used for circulation should be wide enough for the specific forklift in use, and every equipment manufacturer will recommend a safe aisle width for their vehicles. For more details regarding aisle width, read this article.

Beam without (left) and with (right) a safety pin, stamped pin shape is visible.
Figure 2. Beam without (left) and with (right) a safety pin, stamped pin shape is visible. (Source: ECO Racking)

Considering Load Capacity & Pallet Rack Compatibility

While load capacities may exceed 5000lb per pair of beams, the safety pin requirement remains at 1000lb each, so 4000lb per pair of beams. This means that some light loads could be supported by safety pins alone; however, this is never a safe condition and should be immediately addressed. Safety pins are installed only as a preventative measure to ensure the main beam connectors remain engaged. They are never used to support any load or increase racking capacity.

Safety Pin Installation

It is important to verify that all beam connectors are properly installed in the columns before installing safety pins and that the safety pins are compatible with the type of racking. An incompatible pin may not prevent the beam from becoming disconnected.

Now that the importance of having properly installed safety pins is clear, it should be no surprise that safety pins must be installed in all racking systems that are loaded or unloaded using material handling machinery (CSA A344 Section 11.3.1, ANSI MH16.1 Section 5.4.2). Safety pins are not required on racking loaded by hand, where a beam is less likely to become disconnected. However, using safety pins in such cases is always encouraged as they are low-cost, and machine loading could always be used in the future.

Choosing the Right Type of Safety Pin

There are many styles of safety pins available for purchase in case a safety device is not already integrated into the beam connector design. Most can be categorized as either permanent or removable pins. The distinction is that permanent pins are installed with basic tools (wrenches), whereas removable pins require no tools to install or remove. Removable safety pins offer slightly less protection, as there is nothing, except friction and gravity, preventing them from moving out of the proper position by vibrations or contact with pallets (highlighting the need for regular rack inspections to ensure everything is still present and engaged.)

Removable safety pins generally have faster installation times and are available at a very low cost; some styles are made by stamping the shape from excess material, leaving behind a drop pin-shaped hole on the beam connector. Seeing a safety pin stamped from the beam material is often a hint to the manufacturer’s suggested safety pin shape.

Here are a few common safety pin styles:

Removable J Pin

Installed by dropping through aligned holes in the column and beam connector.
Removable J Pin
Permanent Bolt Pin

Installed by threading through aligned holes in the column and beam connector or secured by a nut on the backside.
Permanent Bolt Pin
Removable Clip Style Safety Pin

Installed by hooking on the beam connector and passing the round pin through aligned holes in the upright column and beam connector.
Removable Clip Style Safety Pin
Removable Stamped Safety Pin

Installed by dropping through aligned holes in the rack column and beam connector.
Removable Stamped Safety PIn
Removable Stamped Safety Pin

Installed by dropping through aligned holes in the column and beam connector.
Removable Stamped Safety Pin

When selecting a safety pin style, it is important to consult the rack manufacturer’s recommendations or a qualified engineer. Some might recommend using stamped pins with square edges, whereas others may suggest using round pins. In warehouses where racking is frequently rearranged, there is a small benefit to using removable drop-style pins, where easy installation and removal are desired. However, permanent safety pins can be recommended for warehouses that do not see frequent rack modifications so that once installed, they remain in place and function more efficiently. Always remember that adding, moving, or removing beams affects the load capacity of your racks, and corresponding LARC drawings are required.

Add Safety Pins to Your Rack Inspection Checklist

Now that you are more familiar with rack safety pins and their use, be sure to include them on your checklist for your regular warehouse inspections. Read this article for a complete list of all that needs to be inspected on racking. Paying attention to safety pins and replacing missing or damaged ones will ensure the safety of all warehouse employees – especially those working near your pallet racks. If ever you are in doubt, contact a rack safety partner for advice.


Rack Manufacturers Institute, Inc. (September 30, 2020) How Point Loads and Uniformly Distributed Loads Affect Safe Rack Design . http://www.rmiracksafety.org/2020/09/30/how-point-loads-and-uniformly-distributed-loads-affect-safe-rack-design/

Damotech D-Shield icon About
Damotech

YOUR RACK SAFETY EXPERT

Welcome to the world of Damotech, the first and largest rack safety solutions specialist in North America. With its lines of rack protection and repair products, Damotech strives to put an end to the endless cycle of upright replacement by focusing on warehouse safety and the permanent elimination of recurring rack damage. Through our engineering services, we will help create a safer working environment for you and your employees, bringing you true peace of mind while saving you money in the process.

LEARN MORE ABOUT DAMOTECH Right Arrow Icon