Installing racking might seem straightforward, but you’d be surprised how often warehouses end up with systems that are inefficient, unsafe, or downright costly to maintain. Over the years, Erect-A-Rack has helped countless businesses fix the consequences of poor planning, rushed installs, and mismatched designs.
To save you time, money, and headaches, here are the seven most common warehouse racking mistakes and how to avoid them.
1. Poor Layout Planning
Jumping into a racking install without a detailed layout is like building a house without blueprints.
Why it’s a problem:
- Creates bottlenecks and safety hazards
- Limits forklift access
- Wastes valuable space
How to avoid it:
- Engage a professional racking designer
- Map out pick paths, forklift lanes, and high-traffic zones
- Allow for future growth in your design
2. Choosing the Wrong Racking System
Not all racks are created equal and using the wrong one can lead to underutilised space or product damage.
Common mismatches include:
- Using selective racking for low-turnover bulk items
- Storing long products on standard pallet racking
- Overloading long span shelving
How to avoid it:
- Match the system to your inventory and picking method
- Explore options like cantilever racking or long span shelving when needed
- Ask an expert for a tailored recommendation
3. Ignoring Compliance Requirements
Australia has strict standards for warehouse racking and for good reason.
What can go wrong:
- Fines for non-compliance
- Increased risk of collapse
- Voided insurance claims
How to avoid it:
- Ensure your system complies with AS 4084-2023
- Display load signage on every rack end
- Book regular inspections with a licensed provider
4. Overloading Racks
Just because a pallet fits on a beam doesn’t mean the rack can handle the weight.
Risks include:
- Structural failure
- Safety breaches
- Damage to stock and equipment
How to avoid it:
- Know your rack’s rated load capacity
- Train staff on weight limits
- Inspect racking regularly for signs of stress or damage
5. Poor Installation Practices
A racking system is only as strong as its installation. DIY or underqualified installers can cause more harm than good.
Problems include:
- Improper anchoring
- Misaligned beams
- Inadequate bracing
How to avoid it:
- Use a qualified and experienced installer like Erect-A-Rack
- Get engineering sign-off for every install
- Schedule post-install inspections
6. Neglecting Maintenance and Inspections
Out of sight shouldn’t mean out of mind. Racking is a critical part of your operation treat it that way.
Consequences of neglect:
- Progressive wear and tear
- Undetected impact damage
- Compliance violations
How to avoid it:
- Schedule annual racking inspections
- Replace damaged components immediately
- Encourage staff to report incidents
Learn more about racking inspections and safety compliance.
7. No Room for Flexibility
A rigid racking layout might work today, but what about next year?
Why it’s an issue:
- Limits ability to adapt to changing stock profiles
- Makes future expansion costly and disruptive
- Locks you into inefficient workflows
How to avoid it:
- Choose modular systems that can be reconfigured
- Leave room for future expansion
- Plan with a 3- to 5-year horizon
Final Thoughts
Mistakes in warehouse racking don’t just slow you down they can be dangerous and expensive. The good news? They’re all avoidable with the right planning and expert help.
At Erect-A-Rack, we don’t just sell racking. We partner with you to design, install, and maintain systems that work today and grow with your business tomorrow.
Need a second opinion or a fresh start? Contact us today to talk with our team.
