Can You Work Under Pallet Racking

Warehouses and distribution centers often involve employees working near or under pallet racking systems. Tasks such as picking goods, routine inspections, or forklift operations naturally raise the question: Can you safely work under pallet racking? This article explores the structure, risks, regulations, and best practices for ensuring safety.

What Is Pallet Racking?

Pallet racking is a high-density storage solution designed to hold palletized goods. Common types include selective pallet racking, drive-in racking, push-back racking, and shuttle racking. While they maximize space and improve efficiency, it’s crucial to remember these systems are built for storing heavy loads, not as designated workspaces beneath them.

Understanding Pallet Racking Structures

Pallet racking systems are primarily designed to store pallets and their loads efficiently, maximizing warehouse vertical space and improving inventory organization. They are not inherently intended as “work areas”—meaning workers generally should not perform picking, packing, or other operational tasks while standing on or within the racking itself.

Common pallet racking structures include:

Selective Racking: The most flexible type, allowing direct access to every pallet. Ideal for warehouses with diverse inventory and frequent product rotation.

Drive-In Racking: Enables forklifts to drive directly into the racking lanes, suitable for high-density storage of similar products.

Push-Back Racking: Pallets are loaded onto wheeled carts that move along rails, allowing last-in, first-out (LIFO) inventory management while saving aisle space.

Risks of Working Under Pallet Racking

There are several dangers associated with standing or working under pallet racks:

Falling objects: Pallets, cartons, or products may shift and drop unexpectedly.

Forklift collisions: Impact from equipment can destabilize racks and cause collapses.

Overloading: Exceeding rack weight capacity can result in structural failure.

Compliance concerns: Injuries caused under racks can lead to legal penalties and liability.

Safety Regulations and Standards

Warehouse safety is governed by standards such as OSHA in the U.S. and equivalent agencies globally. These regulations emphasize:

Correct installation and anchoring of racking systems.

Routine inspections for damages, corrosion, or misalignment.

Employee training in safe storage and material handling.

Clear signage and load capacity labels.

Employers must comply with these requirements to ensure workplace safety and avoid fines.

When It May Be Considered Safe

While pallet racks are not designed for work underneath, controlled situations can reduce risks:

Certified installation: Professionally engineered racks with proper load ratings.

Safety accessories: Use of safety mesh decking, pallet supports, backstops, and anti-fall barriers.

Restricted work: Limiting work beneath racks to brief, supervised tasks.

PPE use: Helmets and safety gear to protect workers from falling objects.

Safer Alternatives

Instead of relying on employees working beneath pallet racks, consider safer approaches:

Dedicated picking systems: Use carton flow or longspan shelving for manual picking.

Mezzanine floors: Add platforms to create safe working areas separate from racking.

Automation: Implement conveyors, shuttle systems, or robotics to reduce human exposure.

Conclusion

So, can you work under pallet racking? The answer is only with caution, and never as a standard practice. Pallet racks are storage structures, not workstations. To protect employees, businesses should invest in proper rack design, regular inspections, safety accessories, and alternative solutions that keep workers out of hazardous areas.