Damage Assessment & Inspection
A professional inspection tells you exactly what's wrong, what's safe, and what needs to happen next — measured against ANSI/RMI MH16.1 standards with a clear, prioritized repair report.
What We Examine
Every assessment covers the full structural system — not just the point of visible damage. One forklift strike can affect components well beyond the impact zone.
Upright Frames & Columns
We measure deflection in all planes — front-to-back, side-to-side, and twisting — against ANSI/RMI MH16.1 tolerance thresholds. Damage to a column compromises the entire frame's rated load capacity.
Beams & Step Connectors
We inspect beam profile for bowing and deformation, verify weld integrity at both ends, confirm proper step connector engagement, and check that all safety locking pins are present and functional.
Cross-Braces & Diagonal Struts
Horizontal and diagonal struts resist racking and sway forces. We check each strut for bowing exceeding ½ inch, damaged welds at connection points, and any missing or bent bracing members.
Base Plates & Floor Anchors
We inspect base plate condition for deformation and cracking, verify all anchor bolts are present and properly torqued, and check for any concrete cracking or floor movement around anchor points.
Plumb & Alignment
Racks that are out of plumb — leaning forward, backward, or laterally — redistribute loads in ways the system was not designed to handle. We measure deviation with levels and document any correction required.
Load Placards & Compliance Markings
OSHA and ANSI require every rack row to display a current load capacity placard. We verify placard presence, confirm the information is accurate for the current configuration, and note any that need replacement.
Deflection Thresholds We Measure Against
ANSI/RMI MH16.1 establishes specific deflection tolerances for each rack component. These are not estimates — they are the engineering-based limits beyond which a component must be removed from service and repaired or replaced before the rack can be reloaded.
Understanding these thresholds is what separates a professional inspection from a visual walk-through. We document every measurement and flag any component at or approaching its limit.
Note: For beams, the formula uses actual beam length. A 96-inch beam has a maximum allowable deflection of 96 ÷ 180 = 0.53 inches.
| Component | Max Allowable | Measured How |
|---|---|---|
| Upright Column | ½ inch (12.7 mm) | Widest deflection gap measured front-to-back, side-to-side, and at column corners |
| Horizontal Strut | ½ inch (12.7 mm) | Bowing measured at mid-span of strut in lower upright sections |
| Diagonal Brace | ½ inch (12.7 mm) | Mid-span bowing; connection integrity at both weld points |
| Pallet Beam | Length ÷ 180 | Vertical bowing measured at mid-span under rated load conditions |
| Frame Plumb | Per RMI guidelines | Level measurement at multiple heights; total lean from vertical documented |
Conditions That Require Unloading Now
These five conditions cannot wait for a scheduled assessment. Any rack displaying these issues must be unloaded immediately and kept out of service until professionally repaired.
Unanchored or Loose Frame
Missing anchor bolts or a frame with any visible movement from its base position.
Severe Beam Damage
Any beam with visible deformation, cracked welds, or step connectors that are disengaged or broken.
Creased or Buckled Upright
A sharp crease or fold in the column steel — not a gradual bow — indicates the column has exceeded its yield point.
Excessive Strut Damage
Multiple missing or severely bent struts in the same frame, compromising the frame's structural integrity as a whole.
Multiple Damaged Bays
When damage spans more than one adjacent bay, the full row should be unloaded pending assessment of the structural interaction between frames.
What You Receive After Every Assessment
An inspection without documentation is just a conversation. Every Alloy assessment produces a written record you can act on — and rely on if OSHA asks.
-
Photo-Documented Damage Report Every damaged component photographed and identified by location, with measurements and condition notes.
-
Priority Classification Damage ranked by severity — immediate action required, repair within 30 days, or monitor — so you can allocate resources appropriately.
-
Repair Recommendation per Component Each damaged item receives a specific recommendation: repair kit, full replacement, or guarding installation.
-
Load Placard Audit Confirmation of placard presence and accuracy across all rack rows, with replacements provided where missing or outdated.
-
Compliance Documentation Written record of the inspection scope, findings, and recommended corrective actions — appropriate for OSHA compliance files.
One-Time Assessment or Ongoing Program
Both options use the same inspection process and deliver the same documentation. The difference is frequency — and how much risk you carry between inspections.
One-Time Assessment
A single, comprehensive inspection of your facility's rack system — appropriate for post-incident evaluations, pre-purchase due diligence, or facilities without an existing inspection record.
- Full facility rack inspection, all components
- Damage report with photos and priority classification
- Repair recommendations and cost-of-action guidance
- Load placard audit and replacements as needed
- OSHA-appropriate compliance documentation
Scheduled Inspection Program
Recurring inspections on a monthly, quarterly, or annual schedule — customized to your facility's traffic intensity and operational risk profile. High-throughput facilities with active forklift traffic benefit most from regular intervals.
- All one-time assessment deliverables, repeated each cycle
- Damage tracking over time — trend identification before failures
- Inspection history on file for OSHA compliance documentation
- Priority response for between-inspection incidents
- Frequency recommendation based on your specific operation