Pallet Rack Safety: 5 Reasons Not to Use Old Building Code in Storage Rack Design

Engineering advances and updated methodologies are updating building codes and are crucial for ensuring the safety of both the stored items and personnel

It’s not unusual for a distribution center operator to request additional racking be added many years after the initial storage and handling system was installed. If the current racking is still doing its job 10, 20 or 30 years later, it would make sense to request the rack manufacturer simply replicate the initial design. But this may not be the best solution for pallet rack safety.

“Rack manufacturers like Steel King design their storage and racking systems to last a long time, but the engineering that goes into a design advances through the years,” notes Amit Kutumbale, Director of Engineering at Steel King.

Those engineering advances – especially relating to seismic and stability calculations – are addressed in a two-part article in the Rack Safety Blog. Part 1 and Part 2 talk about updated methodologies for seismic and stability calculations and noting how adherence to the updated codes is crucial for ensuring the safety of both the stored items and personnel.

Based on today’s knowledge of engineering and resulting code updates, using an older design could impose liability that can be very costly.

“From a static load perspective, storage racking designed to an older code may still be rated to support, for example, a maximum 5,000 pounds per shelf,” said Kutumbale. “However, under the new IBC and the referenced MH16.1 Standard, which introduced frame stability checks involving inelastic second-order methods, the system may no longer be considered acceptable today.”

Whether you’re looking to add on to an older pallet rack system or recreate an older system for another area of your facility, here are five key reasons you should consider redesigning your storage racks to newer building codes.

Five Key Reasons to Follow Current Code

1. Safety and Structural Integrity

Newer building codes often include updated seismic design requirements, load combinations, and material specifications aimed at enhancing the safety and structural integrity of buildings and structures. “Evaluating existing storage racks against these updated requirements helps ensure that they can withstand potential hazards, including seismic events, wind loads, and other environmental factors,” says Kutumbale.

2. Code Compliance

Building codes are legal documents that set minimum requirements for the design, construction, and maintenance of structures. “Adhering to the latest building codes ensures that you are compliant with the latest regulatory requirements,” says Kutumbale. This helps mitigate liability risks for property owners, designers, and operators of storage facilities.

3. Risk Management

Structural failures or deficiencies in storage racks can pose significant risks to personnel safety, inventory loss, and business continuity. Upgrading to newer building codes can help mitigate those risks by implementing more robust design practices, performance-based criteria, and quality assurance measures.

4. Industry Standards and Best Practices

In addition to building codes, industry standards and best practices for storage rack design and construction are continually evolving. Upgrading to newer building codes allows storage rack systems to incorporate the latest advancements in material technology, structural analysis methods, and construction techniques, leading to more efficient and resilient designs.

5. Insurance Requirements

Insurance companies may require compliance with the latest building codes and standards as a condition for providing coverage. Ensuring that storage racks meet current code requirements can help facilitate insurance coverage and reduce insurance premiums by demonstrating a commitment to risk management and safety.

Overall, while there may be costs associated with redesigning storage racks to newer building codes, the benefits in terms of safety, compliance, risk management, and long-term performance far outweigh the initial investment. It’s essential to work with qualified structural engineers and building professionals to assess the existing storage rack systems and develop appropriate retrofit or redesign strategies based on the latest building codes and industry standards.

Contact Steel King Industries with any questions about storage rack design, or if you’d like to get started you can find a partner to work with from our nationwide network of distributors.