Rack Collapse: A Serious Problem with a Smart Solution


Rack collapse is one of the most dreaded scenarios in any warehouse or distribution centre. It can cause serious injuries, fatalities, property damage, and operational disruptions. According to the Occupational Safety and Health Administration (OSHA), rack collapse is among the top 10 causes of warehouse accidents in the United States. The annual cost of rack collapse incidents is estimated at $36 billion.

While there are no official statistics on the cost of rack collapse incidents in the UK, some estimates suggest that it could be as high as £1.5 billion per year. This figure takes into account the direct costs of repairing or replacing damaged racks, inventory, and equipment, as well as the indirect costs of lost productivity, business interruption, legal claims, and reputational damage. Moreover, rack collapse can have a devastating human toll, as it can result in serious injuries or fatalities for warehouse workers and visitors.

But what causes rack collapse? And more importantly, how can it be prevented? In this document, we will explore the common factors that contribute to rack collapse, such as overloading, improper installation, poor maintenance, and human error. We will also provide an overview of our racking safety system developed and leading the way in innovation, providing a smart solution to a serious problem.

Causes of Rack Collapse

Rack collapse can occur due to a variety of reasons, but some of the most common ones are:

•     Overloading: This is when the racks are loaded beyond their design capacity, either by weight or by volume. Overloading can cause the racks to buckle, bend, or break, resulting in a domino effect that can bring down the entire row or aisle.

•     Improper installation: Racks not installed according to the manufacturer's specifications, or when they are not anchored to the floor or wall properly. Improper installation can compromise the structural integrity and stability of the racks, making them more susceptible to collapse.

•     Poor maintenance: Racks not inspected, repaired, or replaced regularly, or when not kept clean and free of debris. Poor maintenance can lead to corrosion, rust, cracks, or damage that can weaken the racks and make them more prone to collapse.

•     Human error: Racks can be mishandled, bumped, or hit by forklifts, pallet jacks, or other equipment. Human error can also occur when the racks are loaded or unloaded incorrectly, or when the pallets are not aligned or secured properly. Human error can cause the racks to lose balance, tilt, or shift, resulting in a collapse.

Solution: Rack Collapse Prevention Ltd.’s Racking Safety System

While a rack collapse can have devastating consequences, it can also be prevented with the right measures and technology. Rack Collapse Prevention was developed and designed specifically to prevent and mitigate rack collapse incidents.

Our racking safety system is compatible with any type of rack, pallet, or product, and can be customized to suit the specific needs of each client. Our racking safety system is also easy to install, and can provide significant savings in terms of time, money, and resources, and a reduction in insurance.

Successfully implemented by many clients across different sectors and industries, including Oakland International, a multi-temperature supply chain specialist. Here is what they have to say about their experience with our racking safety system:

Testimonial: “Oakland International was looking for a warehouse safety solution that would give us the confidence that we were providing the safest possible working environment for our team members while also protecting the business from the potential risks associated with a full-scale racking collapse.

“…We are absolutely convinced by the effectiveness of Rack Collapse Prevention’s pallet racking safety system, which is now installed in all our warehouses.”


We have over 30 years of food and storage industry experience and can help find and eliminate the risks for warehouse operators of storage facilities of pallet racking failure. Rack collapse is a significant issue that can affect the safety, productivity, and profitability of any warehouse or distribution centre. By installing our racking safety system rack collapse becomes a concern of the past. A smart and simple solution which stops collapse events and provides confidence and security for warehouse operators, managers and business owners.