While it may seem like a minor issue in the grand scheme of warehouse management, pallet rack push-through can actually have serious consequences. It can damage products and equipment, cause safety hazards for workers, and lead to costly repairs and replacements. That’s why it’s important to take preventive measures to avoid pallet rack push-through in your warehouse. Let’s explore some of the most common causes and tips for reducing the risk of pallet rack push-through.
Understanding Pallet Rack Push-Through
Pallet rack push-through is a common safety hazard in warehouses, occurring when forklifts or other material handling equipment accidentally push pallets off the back of racking systems. When push-through occurs, it can cause damage to both the products and the racking system itself. It can also create a domino effect, causing multiple pallets to fall and potentially injuring workers in the process.
Why does pallet rack push-through matter? As mentioned, pallet rack push-through can lead to damaged products and equipment, safety hazards for workers, and costly repairs. It can also disrupt workflows and cause delays in fulfilling orders, resulting in lost productivity and potential revenue loss. Basically, push-through can completely throw off your warehouse operations. And if left unchecked, it can become a recurring problem that eats into your business’s bottom line.
Common Causes of Pallet Rack Push-Through
Understanding the common causes of pallet rack push-through will allow you to implement prevention measures in your warehouse. Let’s take a closer look at some of these factors:
- Improperly stacked pallets: When forklifts push pallets that are unevenly stacked, they can easily topple over.
- Age and condition of pallets: Old or damaged pallets are more likely to break or tip over, leading to push-through incidents.
- Rack overloading: Heavy loads that exceed the racks’ weight capacity can cause them to collapse under pressure.
- Poor maintenance: Worn out or damaged rack components, such as beams and braces, can compromise the structural stability of the entire racking system.
- Inadequate training: Without proper training on how to handle and store pallets, employees may unintentionally cause push-through incidents.
- Lack of safety measures: Inadequate safety measures, such as lack of guardrails or failure to use rack safety straps, can increase the risk of push-through accidents.
- Forklift speed and operator error: High speeds and operator errors, such as not paying attention to the surrounding area, can lead to push-through incidents.
- Forklift design: Certain forklift designs, such as those with an extended reach or elevated mast, can increase the risk of push-through accidents.
- Poor warehouse layout: A poorly designed warehouse layout with narrow aisles and inadequate clearance can make it more difficult for forklift operators to maneuver, increasing the chances of push-through incidents.
- Environmental factors: Wet or slippery floors, poor lighting, and other environmental factors can also contribute to push-through incidents.
As you can see, many different factors can contribute to push-through incidents, making them difficult to predict and prevent. But with proper precautions and controls in place, you can minimize the risk and keep your warehouse safe.
How To Avoid Pallet Rack Push-Through
How can you reduce the risk of pallet rack push-through in your warehouse? Here are some practical tips to help you prevent this type of accident.
Proper Loading Techniques
One of the first steps to prevent pallet rack push-through is to load pallets correctly. This includes stacking them evenly and securely, using the appropriate size and type of pallets for your racks, and avoiding overloading. You can also use safety equipment, such as rack safety straps or load stops, to secure the pallets in place.
Proper Pallet Conditions
Ensure all pallets are sturdy and in good condition before using them for storage. If you notice any damage or weak points, replace the pallet immediately to avoid potential push-through accidents. It’s also a good idea to rotate older pallets out of use and invest in new ones on a regular basis to maintain their structural integrity.
Regular Maintenance and Inspections
Regular maintenance and inspections of your pallet racking systems are crucial to identifying any potential issues before they cause accidents. Inspect all components, including beams, braces, anchors, and uprights, for damage or wear on a regular basis. Replace any damaged parts immediately and perform load capacity checks periodically.
Employee Training and Education
Properly training your employees on how to handle, store, and stack pallets is essential to preventing push-through incidents. Make sure all employees are familiar with the weight capacity of the racks and understand the importance of proper loading techniques. Conduct regular safety training sessions to reinforce these practices.
Safety Measures
Installing safety features such as guardrails, wire mesh panels, or rack end protectors can help prevent pallets from falling off racks. Also, consider using forklift speed limiters or implementing strict rules on vehicle speed within the warehouse.
Forklift Design Considerations
When purchasing or leasing forklifts, consider their design features and how they could impact push-through incidents. Choose a forklift with good visibility and maneuverability, and avoid models with extended reaches or elevated masts if possible.
Warehouse Layout
Design your warehouse layout with sufficient aisle width and clearance for forklifts to maneuver safely around racks. Consider implementing designated areas for loading and unloading pallets to reduce the risk of push-through incidents in high-traffic areas.
Environmental Conditions
Be aware of environmental factors that can contribute to push-through accidents. Keep floors clean and dry, ensure proper lighting throughout the warehouse, and address any potential hazards promptly.
Pallet rack push-through is a serious safety hazard that can result in worker injuries and damage to inventory. By understanding the common causes and implementing these practical tips, you can reduce the risk of push-through incidents in your warehouse.
By keeping instances of push-through to a minimum, you can create a safer and more efficient working environment for your employees, as well as save time and money on inventory replacement and repairs. While lowering the risk of push-through may require some initial investment and effort, the long-term benefits far outweigh the costs.
If you need help with pallet racking systems or implementing safety measures, consult Direct Pallet Racking. Our team of experts can offer advice on how to optimize your racking system to minimize the risk of push-through. We also carry products like safety bollard posts, which can help you fortify your warehouse’s boundary and prevent forklifts from accidentally pushing pallets off of racks.
