Logistics and supply chain businesses often operate so quickly that it is easy to forget how they rely so heavily on systems so robust and fundamental that they often fade into the background, such as warehouse racking.
Along with the pallet and the forklift, the racking system is critical to the effective operation of any logistics system, and it is almost impossible for many companies to function without it.
Because of this, a major concern for a lot of warehouse owners and operators is the lifespan of the racking units, in order to minimise the amount of significant disruption caused by major repairs or replacement of a rack unit.
It is also essential for safety reasons, as it allows warehouses to keep track of which parts of the racking system may need to be replaced and allows for a swift and safe transfer of materials.
Many manufacturers have a recommended operating lifespan, which tends to range from between a decade to up to 25 years, depending on make, model and materials.
However, these estimates assume ideal operating conditions and many warehouses have somewhat variable operating and environmental factors that can have a detrimental effect.
What Factors Affect The Lifespan Of Racking?
There are countless variables when it comes to racking, but many of these individual factors can be categorised into various groups.
The first set is environmental conditions, such as operating temperatures, humidity, exposure to moisture and corrosive substances, all of which can either damage the racking directly or affect the galvanised coating or corrosion-resistant finish of the metal.
This is a bigger issue with coastal facilities such as docklands, which are significantly affected by the salty sea air, as well as businesses that regularly handle volatile and corrosive materials.
As well as this, one of the biggest factors that affect how long racking can be used is how often they are used.
If a racking system frequently experiences loads that are higher than they are rated for, it will eventually fail over time. Similarly, forklift impacts or other breaches of operational guidelines can cause structural damage that compounds over time.
Whilst this can be concerning, many of these factors can be mitigated by a robust set of operating guidelines, risk assessments made based on the holistic conditions of the warehouse itself, and establishing a protocol for removal and replacement that minimises disruption where possible.
There are some shelving units, materials or finishes that are more resistant to environmental factors than others, and whilst this will come with a cost premium, the savings will come through longer uninterrupted function and fewer replacements.
A firm set of operating guidelines, including speed limits for forklifts, clear warehouse markings and signage to clearly display the rules will help to prevent damage and harm caused to the racking and anyone working around it.
Finally, the modular nature of racking means that it can be removed and replaced in segments, and an efficient protocol to do so will mean that most of the rest of the warehouse can be used whilst the racking is being professionally replaced and reinstalled in place.
