{"id":1964,"date":"2019-03-26T06:15:59","date_gmt":"2019-03-26T13:15:59","guid":{"rendered":"https:\/\/www.speedrackwest.com\/?p=1964"},"modified":"2025-08-18T13:59:33","modified_gmt":"2025-08-18T13:59:33","slug":"warehouse-collapse","status":"publish","type":"post","link":"https:\/\/www.speedrackwest.com\/blog\/warehouse-collapse\/","title":{"rendered":"How Did This Warehouse Collapse? (& How to Avoid It)"},"content":{"rendered":"\n

You may have seen this video making its rounds on the internet – every warehouse manager\u2019s nightmare. A warehouse collapse.<\/span><\/p>\n\n\n\n

But how did it happen? <\/span><\/p>\n\n\n\n

Obviously, the forklift hitting the rack was the direct cause. But, it is shocking to see such a gentle bump cause a total rack collapse. We\u2019re confident that there\u2019s something else going on here.<\/span><\/p>\n\n\n\n

When a disaster like this occurs, there is usually more than one contributing factor. Here are some of the most common causes of pallet rack<\/a> system failure, whether acting alone or in combination.<\/p>\n\n\n\n

Overloaded Racking Causes a Warehouse Collapse<\/h2>\n\n\n\n

It is clear that those aren\u2019t empty cardboard boxes. It certainly looks like that racking contains full loads. We\u2019d guess that the rack is in a state of overload. The rack exceeds the manufacturer\u2019s recommended loading capacity. This seems like the largest contributing factor to the collapse.<\/span><\/p>\n\n\n\n

Too much deflection is a red flag that your racking is overloaded. Of course, some deflection is common. However, too much is a recipe for disaster.<\/p>\n\n\n

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\"deflection<\/figure>\n<\/div>\n\n\n

Improper Use<\/h2>\n\n\n\n

Proper training and equipment are integral to the safety and success of any warehouse. Using the wrong material handling equipment, or using the right equipment in an improper way, can lead to catastrophic mistakes like the one in the video above. <\/span><\/p>\n\n\n

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\"Warehouse<\/figure>\n<\/div>\n\n\n

How Can I Limit The Risk of Warehouse Collapse?<\/h2>\n\n\n\n

Manufacturing Defect<\/h3>\n\n\n\n

Mistakes happen in any industry, and racking is no different. It’s always a good idea to inspect the materials yourself, just to be sure there are no issues.<\/span><\/p>\n\n\n\n

In the video above, perhaps the racking was welded improperly or there was another weak point on the racking itself. <\/span><\/p>\n\n\n\n

We\u2019ve also seen a manufacturer ship the incorrect parts (ie, they intended to send 15ga beams<\/a>, but shipped 16ga beams instead). A mistake like that would be almost impossible to identify without cutting the beam apart, removing the paint, and measuring with steel thickness with calipers.<\/span><\/p>\n\n\n\n

Damage to racking is something you need to be conscious of over time. These racks are built extremely sturdy. But if they are repeatedly mistreated over a decade, things can start to wear down.<\/p>\n\n\n\n

Prior Damage<\/h2>\n\n\n
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\"Drill\"<\/figure>\n<\/div>\n\n\n

It’s possible that this wasn’t the first time the racking had been hit. Some parts of the racking may have been damaged in a prior incident. The damaged rack is no longer structurally sound and must be replaced immediately.<\/p>\n\n\n\n

\"Warehouse<\/figure>\n\n\n\n

How Can I Limit The Risk of Warehouse Collapse?<\/h2>\n\n\n\n

Extensive Safety Training<\/h3>\n\n\n\n

Train your people to drive forklifts carefully and load racking carefully. Nothing can substitute for this. A forklift and an earthquake are the biggest risks to your pallet racking<\/a>. You can\u2019t control an earthquake, but you can decide to properly train your people.<\/span><\/p>\n\n\n\n

Follow Warnings or Suffer a Warehouse Collapse<\/h3>\n\n\n\n

Do not, under any circumstances, exceed the engineer\u2019s stated capacity. These rules are there for a reason and the consequences of ignoring them are much more catastrophic than the nuisance of following them. <\/span><\/p>\n\n\n\n

Protect Your Racking<\/h3>\n\n\n\n

You can protect your racking from a forklift or other damage with various safety products:<\/span><\/p>\n\n\n\n