Minor Damage Becomes Major Risks
The Surprising Ways Minor Damage Becomes Major Risks
At first glance, a dented upright or a slightly twisted beam might seem harmless. It’s easy to think“It’s still standing, so it must be fine.”But in the world of pallet racking, even the smallest damage can snowball into serious safety and operational threats.
At Rusch Rack Inspections, we’ve seen how “minor” damage can quietly compromise the entire structural integrity of a system. Here's what most facility managers don't realize
Small Dents Aren’t Just Cosmetic
That nick in the upright from a forklift bump? It may have already reduced the load capacity of the rack. Even a ½" deflection can create stress points that worsen over time especially with daily wear and tear from vibrations, loads, and impacts.
Damage Compounds Over Time
A misaligned beam might not collapse today. But as product loads shift and forklifts make sharp turns near it, the rack becomes more vulnerable. Each unaddressed “minor” issue quietly weakens the system until one day, it fails often without warning.
Inventory Isn’t the Only Thing at Risk
When a rack fails, it’s not just about lost product. It’s downtime. It’s injuries. It’s OSHA citations. One overlooked bolt or bend can lead to chain reactions that cost exponentially more than a proactive inspection ever would.
Quick Fixes Aren’t Always Safe Fixes
We’ve seen racks “patched up” with tape, zip ties, even wood blocks none of which are compliant with RMI standards. These DIY fixes create a false sense of security and hide deeper issues.
So, What Can You Do?
Stay proactive - Schedule regular rack inspections not just annual check-ins but after any incident, relocation, or layout change
Educate your team - Train staff to report even the smallest issues before they grow
Bring in the pros - A trained eye knows what to look for what to document and how to prioritize true risk. Don’t wait for a warning sign that never comes
If you’ve got minor rack damage let’s assess it before it becomes a major event
Call Rusch Rack Inspections today at 616-291-7205
Or visitruschrackinspections.comto book your professional evaluation
