In October 2023, OSHA launched a National Emphasis Program for warehousing operations, meaning federal inspectors are now walking into facilities to check rack safety and other hazards for anyone setting up a new warehouse, which raises the stakes on getting the installation right.
So if you’re staring at a stack of pallet racks wondering whether to assemble them yourself, it pays off to familiarize yourself with the basics. This article explores what new warehouse owners doing DIY Pallet Rack Assembly need to consider
Why Owners Choose the DIY Route
Hiring a professional crew for a warehouse racking installation in a commercial warehouse can easily cost thousands of dollars. For small businesses setting up warehouse operations for the first time, the money would usually be better spent on inventory or hiring.
These crews are often booked weeks or even months in advance, so even if you’re prepared to pay, delays might force new owners to take matters into their own hands.
Setting up a pallet rack storage system yourself saves money, more importantly, it gives you invaluable practical experience with your storage system. There’s no better way to understand the material foundations of your warehouse storage system than building it from the ground up.
Read the Manual Before You Buy
New warehouse owners need to give themselves time to make the right purchasing decisions. There’s often a sense of urgency when setting up a new warehouse, usually because there’s a hard deadline on when the first shipments are set to arrive. Pallet racks come in different styles and sizes, and they need to be comparable with the new warehouse space.
Factors like the following illustrate why ordering the right pallet racks is so important:
- Forklift turning radius
- Weight limits
- Height limits
The more new owners rush the process, the more likely it is that they’ll order something incompatible. Before ordering, take the time to measure things up and ensure that the storage racks are used within safe parameters.
What You Actually Need on Site
Before you swing a single tool, dig out the manufacturer’s assembly instructions and keep them within reach. Every rack system uses slightly different beam clips and anchor specifications, so the generic advice below is no substitute for the actual manual. With that in mind, here’s the basic kit and a few prep steps that save headaches later.
- Rubber mallet
- Four-foot level
- Ratchet set
- Anchor bolts in the manufacturer’s specified type
- Hammer drill if your floor is concrete
The uprights, or vertical frames, are heavy and awkward to get into place. Trying to stand one up by yourself is a sure way to hurt yourself. When doing a DIY installation, you shouldn’t literally do it yourself; enlist a helper or two to ensure safety.
Chalk lines on the floor before you anchor anything. Once an upright is bolted down, moving it means drilling new holes and patching the old ones, so getting it right the first time pays off.
The Steps People Miss
The anchoring stage is where DIY installs tend to go wrong. Every upright needs to be securely bolted into the concrete floor. The manufacturer specifies an anchor type, and it’s important to use the correct size. Improperly anchored racks can easily tip over when a forklift knocks them.
It’s also risky to skip out on plump or level checks. Racks that lean load unevenly, causing the bottom beams to take on more stress. Eventually, the racks will fail since the beams weren’t designed for so much weight. Use a four-foot level on every upright before tightening the final bolts.
When to Call Someone
Hire a pro instead of going DIY when:
- Your warehouse is taller than about 20 feet
- You’re installing more than a dozen bays
- Local code requires a seismic-rated install
- Your city requires a licensed installer’s signature on permit paperwork before your insurance kicks in
Check with your local building department before you commit to a weekend project.
A Safe and Reliable Installation
Most small to mid-sized warehouses can successfully assemble pallet racks themselves if the preparation is done correctly. On the day of installation, owners should meticulously read the manual and verify the level of each upright; these precautions are critical for safety. The National Emphasis Program means that federal inspectors are now going into warehouses. This means that a careful installation is important for the safety of your team and your reputation with OSHA.
If you’re interested in learning more about similar topics, see our other articles.
