I. Problems with Warehouse Racking

1. Problems with unreasonable design
- Size mismatch: If the size of the rack does not match the warehouse space or the size of the goods, it will lead to wasted space or inability to store goods properly. For example, if the rack is too high and the maximum lifting height of the warehouse forklift is limited, it makes it difficult to use the upper rack space; or if the depth of the rack is too deep, it makes it difficult to access the rear part when storing small items.
- Insufficient load-bearing capacity: If the load-bearing capacity of the rack is not accurately calculated, the rack may deform or even collapse. For example, when storing heavier goods, the beams or columns of the rack cannot bear the weight, affecting the safety of goods storage and the service life of the rack.
- Improper passage planning: If the width of the passage between the racks is too narrow, it will affect the efficiency of forklifts and other handling equipment, increasing operation time and collision risks; if the passage is too wide, it will cause wasted space.

2. Material quality issues
- Poor steel quality: Racks are usually made of steel. If the quality of the steel is not up to standard, such as too high or too low carbon content, it may affect the strength and toughness of the rack. During long-term use, rust and corrosion are likely to occur, reducing the safety and service life of the rack.
- Poor surface treatment: If the quality of the coating on the surface of the rack is poor, such as uneven spraying or poor adhesion, it will cause the rack to be easily eroded by humid air and chemicals, accelerating the damage of the rack.

3. Installation problems
- Insufficient installation accuracy: During the installation process, if the verticality of the columns and the horizontality of the beams do not meet the requirements, the rack will be subjected to uneven force. For example, column inclination may cause lateral force on the rack after loading goods, affecting the stability of the rack.
- Unstable connection: If the connection method between the various parts of the rack is incorrect or the quality of the connecting pieces is poor, such as loose bolts or loose hooks, the rack will shake or shift during use, and in severe cases, it may cause the rack to collapse.

4. Usage and maintenance issues
- Overload use: In actual warehousing operations, in order to save space or improve storage capacity, there may be cases of overloading goods. This will cause great damage to the rack, shorten the service life of the rack, and even cause safety accidents.
- Collision damage: During operation, forklifts or other handling equipment may accidentally collide with the rack, causing the parts of the rack to deform or fall off. Frequent collisions will seriously affect the structural integrity of the rack.
- Lack of maintenance: If the rack is not maintained for a long time, such as not cleaning dust and debris in time, and checking the wear and tear of parts, the performance of the rack will gradually decline. For example, the rollers of roller racks may become inflexible due to dust accumulation.

II. Solutions

1. Addressing unreasonable design issues
- Size optimization: Before designing the rack, the spatial dimensions of the warehouse should be accurately measured, and the size, shape, and storage method of the goods should be fully considered. Based on the maximum lifting height and operating space of the forklift, the height of the rack should be reasonably determined; based on the size and access frequency of the goods, the depth and number of layers of the rack should be adjusted. For example, for situations with many small items, shallow multi-layer racks can be designed to facilitate access to goods.
- Load-bearing capacity calculation: Using scientific calculation methods, accurately calculate the load-bearing capacity of the rack based on factors such as the weight and distribution of goods. Relevant mechanical principles and rack design standards can be referenced to select appropriate rack materials and structures. For example, for heavy goods storage areas, rack structures with thickened beams and reinforced columns are used.
- Passage planning adjustment: Based on the size and operating requirements of the handling equipment, reasonably plan the width of the passages between the racks. Generally, the width of the forklift passage should meet the maximum turning radius and safety distance requirements of the forklift. At the same time, ring passages or reserved cross passages can be considered to improve handling efficiency.

2. Addressing material quality issues
- Material selection control: When purchasing rack materials, reliable steel suppliers should be selected. The composition, strength, and toughness of the steel should be strictly inspected to ensure that they meet the rack design requirements. For example, the carbon content of the steel is required to be within the appropriate range to ensure the strength and weldability of the rack.
- Surface treatment improvement: Adopt high-quality surface treatment processes, such as high-quality spraying or galvanizing. Spraying should ensure the uniformity and adhesion of the paint layer, and galvanizing should ensure the thickness and quality of the zinc layer. After surface treatment, some protective measures can also be taken, such as applying anti-rust oil, to enhance the corrosion resistance of the rack.

3. Addressing installation issues
- Ensuring installation accuracy: When installing the rack, professional measuring tools such as levels and theodolites should be used to ensure the verticality of the columns and the horizontality of the beams. Installation personnel should be professionally trained and operate strictly according to the installation instructions. For example, during the installation process, regularly check the verticality deviation of the columns and adjust them in time.
- Connection reinforcement: Use appropriate connection methods and high-quality connecting pieces. For bolt connections, tighten the bolts according to the specified torque; for hook connections, check the quality of the hooks and the tightness of the connection. After installation, the rack can also be reinforced as a whole, such as adding diagonal supports and other auxiliary support structures, to enhance the stability of the rack.

4. Addressing usage and maintenance issues
- Preventing overload: Clearly indicate the load limit of the rack and mark it prominently in the warehouse. At the same time, train warehouse personnel and emphasize the dangers of overloading. When storing goods, the weight distribution of goods should be reasonably arranged to avoid local overloading. For example, electronic scales can be used to weigh the weight of goods to ensure that it does not exceed the load-bearing capacity of the rack.
- Anti-collision measures: Set up anti-collision facilities around the rack, such as anti-collision barriers and warning signs. Train forklift operators to improve their operating skills and safety awareness, and reduce the occurrence of collision accidents. At the same time, regularly check the collision situation of the rack and repair damaged parts in time.
- Maintenance Plan Development: Establish a comprehensive shelf maintenance plan, regularly cleaning, inspecting, and maintaining the shelves. During cleaning, remove dust, debris, etc. from the shelves; inspection includes checking for wear and tear, deformation, and connection status of components. For any problems found, promptly repair or replace components. For example, conduct a minor inspection monthly and a comprehensive maintenance check quarterly.