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Warehouse Safety Mistakes

Act to reduce risk and get the issue evaluated.

1. Identify and flag the damage so it’s clearly reported.
2. Secure the area and prioritize the issue, including partial unloading or cordoning off the affected locations if there’s uncertainty.

Because rack damage can be difficult to assess without engineering expertise, a qualified professional should then evaluate the situation to determine the appropriate response.

Damage is prioritized based on risk, not appearance. Issues are classified by severity—unload, high, moderate, or low—but multiple issues at the same location can combine to create a higher overall risk. That’s why damage must be assessed by asset, not in isolation.

It’s also important to note that once damage exists, there is no reliable way to estimate how much load capacity has been lost or to safely compensate by loading less. Damage must be addressed through repair, replacement, or engineering review. Treating findings as data allows risks to be ranked objectively and addressed in the right order.  

Progressive damage is the key warning sign. 

Corrosion is a common example—once it starts, it doesn’t stop. Surface rust may be minor, but section loss (often around 10% steel thickness) signals that structural integrity is compromised and the issue will continue to worsen. Early identification allows corrective action before damage becomes irreversible. 

For pallet racking operated by forklifts, anchoring is typically required to ensure stability and structural integrity. In standard rack systems, operating without anchors is generally not acceptable unless the system was specifically designed and engineered to be freestanding, which is rare.

If a lease restricts anchoring, this becomes a fundamental constraint that must be addressed before normal forklift operation can continue. In some limited cases—such as hand-picking operations or very specific engineered designs—alternative solutions may be possible, but these must be reviewed and approved by a qualified engineer.

In practice, anchoring restrictions often serve as a hard stop until the rack system, operating type, or lease conditions are reassessed with proper engineering input.

Get into a program.

Good intentions don’t stand the test of time, and rack safety isn’t something most warehouse teams can manage consistently on top of daily operations. The facilities that perform best are the ones where leadership invests in a structured rack safety program that runs continuously, reduces repeat issues, and allows operators to focus on running the business—while the system takes care of safety, follow-up, and long-term risk.

Yes, adhesive anchors can be acceptable for pallet racking, but only if they are the specified anchor in the engineered anchorage design. ANSI MH16.1 ties anchor design to ACI 318 Chapter 17.

Adhesive anchors work, but they’re less forgiving. They rely on perfect installation and the right site conditions, and they need cure time. Mechanical anchors are usually quicker and simpler. Either way, don’t swap anchor types on site without an engineer signing off.