Why Every Warehouse Needs an Internal Rack Inspection Process

A rack engineer’s perspective on OSHA compliance, RMI standards, and operational accountability

After years spent designing, inspecting, and repairing pallet racking systems in active warehouses and distribution centers, one thing becomes clear very quickly: most rack failures are not design failures — they are inspection failures.

Warehouse racking is a structural system, governed by engineering standards and subject to workplace safety regulations. Yet it is often treated as temporary infrastructure, even though it routinely supports tens or hundreds of thousands of pounds. Forklift traffic, operational changes, and daily impacts all introduce risk. Without a disciplined inspection process, that risk compounds quietly — until it becomes an incident.

From an engineering standpoint, a formal internal rack inspection program is one of the most effective safety controls a facility can implement.

Racking Is a Regulated Structural System — Not Just Storage

While OSHA does not publish rack-specific design standards, it does hold employers responsible for maintaining safe storage systems under:

• OSHA 29 CFR 1910.176(b) – Secure storage of materials

• OSHA General Duty Clause (Section 5(a)(1)) – Providing a workplace free from recognized hazards

In parallel, the Rack Manufacturers Institute (RMI) publishes detailed engineering guidance through documents such as:

• ANSI/RMI MH16.1 – Specification for the Design, Testing, and Utilization of Industrial Steel Storage Racks

Together, these establish a clear expectation: Rack systems must be maintained in a safe, serviceable condition — and damage must be identified and addressed.

An internal inspection process is how facilities demonstrate that expectation is being met.

Rack Damage Is Cumulative — and Often Structurally Significant

From an engineering perspective, steel rack components are designed with defined tolerances. Once those limits are exceeded, capacity is permanently reduced.

Common high-risk conditions include:

• Upright column dents beyond RMI allowable limits

• Frame twisting or bowing

• Missing or damaged beam safety locks

• Floor anchors that are loose, sheared, or missing

• Load conditions that no longer match the original design

Many of these conditions do not look severe to untrained personnel — but they matter structurally.

RMI explicitly states that damaged components should not be straightened or reused and that impact damage must be evaluated promptly. An internal inspection process is how those issues are identified early, before they become OSHA recordables or insurance claims.

Internal Inspections Reduce Risk — and Cost

From both an engineering and operational standpoint, internal inspections are one of the highest ROI safety measures available.

Early detection allows:

• Planned, localized repairs

• Minimal product relocation

• Controlled downtime

• Documented compliance

Without inspections, damage accumulates until facilities are forced into:

• Emergency unloading

• Full bay replacement

• Operational disruption

• Regulatory scrutiny following an incident

Inspections shift rack maintenance from reactive crisis response to controlled asset management.

What OSHA- and RMI-Aligned Internal Inspections Look Like

An effective internal rack inspection program should include:

1. Routine Visual Inspections

• Conducted weekly or monthly

• Focused on impact zones, aisle ends, and changes in layout or load

• Performed by trained internal personnel

2. Clear Damage Classification

RMI recommends objective damage categorization:

• Green: Acceptable

• Amber: Monitor and schedule corrective action

• Red: Immediate unloading and repair

This removes ambiguity and enables supervisors to act decisively.

3. Documentation and Traceability

• Date-stamped inspection forms

• Photos of damage

• Repair tracking and closeout

• Records available for OSHA inquiries or insurance audits

4. Defined Escalation Protocols

Internal teams must know:

• When to call maintenance

• When to involve a qualified rack professional or engineer

• When bays must be taken out of service immediately

Without escalation rules, inspections become observations — not controls.

Inspections Protect People, Product, and Capital

Racking systems represent a significant capital investment. When maintained properly, they can perform safely for decades. When neglected, they degrade rapidly and unpredictably.

From an engineering risk perspective, internal inspections:

• Support OSHA compliance

• Align with RMI best practices

• Extend rack service life

• Reduce unplanned capital expenditures

• Strengthen insurance defensibility

They are not paperwork — they are risk management tools.

Internal Inspections Do Not Replace Professional Evaluations

Internal inspections are essential, but they are not a substitute for periodic evaluations by qualified rack professionals.

Think of internal inspections as continuous monitoring, and professional inspections as structural validation. Both are required for a defensible safety program.

How EFS Helps

At EF Solutions Group (EFS), we help facilities turn rack safety from a reactive issue into a structured, defensible program.

Our team supports:

• Internal rack inspection program development

• OSHA- and RMI-aligned inspection forms and processes

• Professional rack inspections and damage assessments

• Engineered repair recommendations

• Long-term rack safety and compliance strategies

Whether you need help building an internal inspection process, validating existing racking,

or addressing identified damage, EFS provides expert guidance rooted in engineering and real-world warehouse operations.

Rack safety isn’t optional — and it doesn’t have to be complicated. Let EFS help you protect your people, your product, and your investment.