Warehouse rack collapses are more common in India than people realize. They cause injuries, destroy inventory, and shut down operations. Here's what actually causes them and how to prevent it. 7 Causes of Warehouse Rack Collapse 1. Overloading (Most Common — 40% of cases) Racks designed for 1,000 kg per level get loaded with 1,500 kg "just this once." Over time, beam deflection weakens the structure until catastrophic failure. Prevention: Clear load signage on every bay. Train all warehouse staff. Weigh random pallets monthly. 2. Forklift Impact (30% of cases) A forklift hits an upright at ground level. The impact may look minor — a small dent or bend. But that upright now carries thousands of kilos with compromised structural integrity. One more hit and the entire row can cascade. Prevention: Column guards on all aisle-end frames (₹500-1,500 each). Floor-mounted barriers. Speed limits for forklifts near racks. 3. Wrong Rack for the Application Using slotted angle racks (rated 200 kg/shelf) for palletized goods that weigh 800 kg. This happens when businesses try to save money by using the wrong product. Prevention: Always consult the manufacturer about your actual loads. A proper rack costs less than the
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