Rack System Safety in Industrial Facilities: Periodic Inspections and Load Capacity Management

Rack system safety in industrial facilities extends far beyond initial installation. Periodic inspections, load capacity management, and impact protection are ongoing responsibilities that directly affect operational safety and insurance compliance.

Forklift impacts on rack uprights are among the most common causes of rack damage and collapse in American warehouses. A single impact can compromise the structural integrity of an entire bay, leading to inventory loss, facility downtime, and serious injury risk.

PAS 13 certified rack protection barriers absorb forklift impact energy before it reaches rack uprights. Unlike steel barriers that dent permanently and may still transfer damaging force, PolyCore™ barriers flex, absorb, and rebound — continuing to protect after multiple impacts.

Periodic rack inspections should include assessment of existing barrier protection: Are rack ends protected? Are aisle barriers positioned to prevent fork penetration? Have layout changes left vulnerable areas unprotected? Have previous impacts damaged steel barriers beyond effective protection?

NexGen recommends annual barrier system reviews alongside rack inspections. Our engineers can assess your current protection, identify gaps, and recommend PolyCore™ upgrades where steel barriers have failed or where new traffic patterns have created unprotected zones.