Rack Column Repair vs. Replacement
ROI Calculator

Your Warehouse Info

Total number of frames in your warehouse:

Average percentage of frames damaged per year (%):

Lost revenue for downtime per frame per week, if any ($):

Rack Replacement Info
All costs are per frame. How are costs calculated?

OEM frame (upright) cost ($):

Freight/Shipping cost ($):

Equipment rental cost ($):

Unloading & reloading cost ($):

Dismantling cost ($):

Re-installation cost ($):

Lead time for an OEM frame replacement (weeks):

Rack Repair Info
All costs are per frame. How are costs calculated?

Rack repair kit cost ($):

Freight/Shipping cost ($):

Equipment rental cost ($):

Unloading & reloading cost ($):

Dismantling cost ($):

Installation cost ($):

Lead time for a Damotech repair kit (weeks):

Your busniess email (for personalized results):
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Rack Replacement Costs

When evaluating the cost of replacing racks, it’s essential to consider more than just the price of an upright frame. Several additional costs contribute to the total replacement expense. For example, to replace an upright frame, you must first unload each beam level on both sides of the damaged frame. Only then can you dismantle the rack and proceed with the frame replacement. This process requires labor and equipment, both of which add to the overall cost.

Here’s a breakdown of the typical costs associated with frame replacement (default value used in the calculator):

Rack Repair Costs

Like replacements, rack repairs also come with associated costs. However, in most situations, repairs don’t require unloading, dismantling, or reinstalling racks, resulting in significant labor savings. Since repair kits are installed using proprietary equipment, no rentals are needed. Also, installation generally takes under an hour, minimizing operational disruption and downtime. Best of all, engineered rack repair means you'll most likely never have to fix a repaired location ever again.

Here’s a breakdown of the typical costs associated with frame repair (default value used in the calculator):

Calculator Input Fields

Total number of frames in your warehouse:

This field represents the total number of pallet rack frames in your warehouse. A rack frame, also known as an upright frame, consists of two vertical columns (posts) connected by horizontal and diagonal braces. This number is used to calculate the number of frames damaged each year in your warehouse.

Average percentage of frames damaged per year (%):

This is the average percentage of frames in the warehouse that are typically damaged annually. It helps estimate how many frames need to be repaired or replaced annually.

Lost revenue for downtime per frame per week ($):

This input represents the estimated financial loss incurred each week that a pallet rack frame is out of operation due to damage. When a frame is unavailable, it can disrupt warehouse operations, resulting in lost revenue, delays in product handling, and inefficiencies. This value should reflect the impact of having reduced storage capacity or operational efficiency for each damaged frame. The number entered here is multiplied by the weeks it takes to replace or repair the frame to calculate the total lost revenue due to downtime when the frame is non-functional. Enter 0$ if there is no financial impact for downtime in your warehouse.

Costs:

The default amounts reflect the figures used in our rack column repair vs. replacement infographic..

• Cost of the OEM replacement frame rack or rack repair kit ($)
  Purchase price of the parts and materials needed to obtain the replacement upright frame or rack repair kit.
• Freight/Shipping cost ($)
  Cost of delivering the rack frame or repair kit to your site.
• Equipment rental cost ($)
  Rates for any lifting equipment or platforms required for the operation.
• Unloading & reloading cost ($)
  Fees and labor associated with unloading and reloading the materials onto the rack.
• Dismantling cost $)
  Labor cost for dismantling the rack and removing the damaged components before installing the new ones.
• Installation or reinstallation cost ($)
  Cost related to reinstalling the dismantled rack or installing the repair kit.

Lead time for an OEM frame replacement (weeks):

The number of weeks it takes to get a damaged frame delivered from an OEM manufacturer. This value helps calculate the lost revenue due to downtime caused by the replacement process.

Lead time for a Damotech repair kit (weeks):

The number of weeks it takes to get a pallet rack frame repair kit delivered from Damotech. This value is used to calculate the lost revenue due to downtime during the repair process.

ROI Report Table

Year:

This column represents the year of the analysis, from 1 to 10.

Frames Replaced:

This column shows the number of pallet rack frames replaced in a year. This value is calculated as a fixed percentage of the total number of frames in the warehouse, as damaged frames that are replaced can still get damaged again in subsequent years.

Total Costs for Replacement ($):

This column represents the total direct costs of replacing the damaged frames for that year. This includes all component parts, freight, rentals, unloading, dismantling, and installation. The amount reflects the numbers from our rack repair vs. replacement infographic.

Total Frame-Weeks of Downtime:

This represents the cumulative impact of downtime on racking. It considers the number of frames out of service and their duration of unavailability. It helps assess the impact of downtime in warehouse efficiency.

Lost Revenue for Replacement ($):

This column represents the financial losses caused by downtime while waiting to replace damaged frames with OEM replacements. The lost revenue is calculated based on the lead time for replacement and the cost of downtime per week.

Frames Repaired:

This column shows the number of frames repaired using Damotech repair kits for that year. As frames are repaired, they will no longer need to be repaired in the future, so the number of frames eligible for repair decreases over time.

Total Costs for Repair ($):

This column represents the direct costs associated with repairing damaged frames using Damotech repair kits for that year. This includes repair costs, freight, and installation. The amount reflects the numbers from our rack repair vs. replacement infographic.

Lost Revenue for Repair ($):

This column represents the financial losses caused by downtime while waiting to repair damaged frames using Damotech repair kits. The lost revenue is calculated based on the repair lead time and the weekly downtime cost.

Total ROI ($):

This column calculates the total return on investment (ROI) realized by repairing damaged frames with Damotech kits instead of replacing them with OEM frames. It is the difference between the total costs for replacement plus associated lost revenue, and the total costs for repair plus associated lost revenue. Positive values indicate cost savings from opting for repairs over replacements.