Case Study— A national chain saves $10M a year

HOW A NATIONAL WAREHOUSE NETWORK STOPPED WASTING MILLIONS ON RACK MAINTENANCE

A Real-World Case Study on Safety, Risk, and Smarter Rack Decisions

This case study tells the true story of a national organization operating more than 1,500 warehouse locations that believed it was doing the right thing by prioritizing safety. After a serious employee injury caused by a sudden rack collapse, the company launched an internal rack safety initiative and began aggressively replacing damaged racking.

The intention was good. The results were not.

This case study explains what changed. Inside, you’ll learn:

Why well-intentioned safety programs can still lead to excessive rack replacement
The most common mistakes large organizations make when assessing rack damage
How improper damage classification drives unnecessary costs and downtime
What role engineering expertise plays in separating “repairable” from “replace immediately”
How the company standardized rack safety decisions across hundreds of facilities

Don’t miss out on this must-read case study—fill out the form to access it now!

CASE STUDY SUMMARY

For large warehouse networks, pallet rack damage is inevitable. Forklift impacts happen. Components get bent. Repairs are made under pressure. Over time, what starts as “routine maintenance” can quietly turn into millions of dollars in unnecessary replacement costs—without actually making warehouses safer.

Because rack damage was being misunderstood and misclassified, the company was replacing entire uprights when engineered repairs would have safely and permanently restored load capacity. The result? An average of $10,000 per location, per year in avoidable replacement costs—adding up to more than $10 million annually.

Download the full case study to see exactly what changed, what mistakes were avoided, and how similar results can be achieved in your own operations.

This is not a theoretical success story. It’s a practical lesson in how misinterpreting rack damage can cost millions—and how changing the decision process can reverse that trend.

With the help of Damotech’s engineers, the organization implemented a structured rack safety program focused on correct damage assessment, engineered repairs, and targeted protection. The result was not only a dramatic reduction in maintenance spending but also improved safety, consistency, and confidence across all sites.

If you manage multiple warehouses, oversee safety programs, or are responsible for controlling maintenance budgets, this case study shows what’s possible when rack safety decisions are based on engineering—not assumptions. Download it now and see for yourself.

HOW A NATIONAL WAREHOUSE NETWORK STOPPED WASTING MILLIONS ON RACK MAINTENANCE

A Real-World Case Study on Safety, Risk, and Smarter Rack Decisions

Fill out the form to download the case study

CASE STUDY SUMMARY

Engineering Services

Rack & Warehouse Protection

Rack Damage Repair Kits

Safety Solutions

Content Offers

Safety Videos

Educational Content

Company

Contact

Support

Careers