As the core load-bearing equipment in warehousing, heavy-duty shelving and its components are subjected to prolonged pressure from goods, environmental corrosion, and operational impacts, making them prone to wear or failure. According to the China Warehousing and Distribution Association’s “ 2024 "Annual Shelf Safety Operation and Maintenance Report" data, approximately 78% The safety incidents involving shelving units stem from the failure to replace vulnerable components in a timely manner or from improper replacement procedures. This article provides enterprises with a standardized operational guide by clearly defining the types of vulnerable parts, outlining detailed disassembly and replacement steps, and emphasizing thorough inspection and maintenance—ensuring the safe operation of shelving systems.

(Shelf Accessories)

I. Identification of Wear Parts in Heavy-Duty Racks and Analysis of Failure Causes

Accurately identifying vulnerable parts and understanding their wear patterns are essential for efficient replacement. Heavy-duty shelving systems typically have vulnerable components concentrated in “ Load-bearing connection ““ Security Protection ““ Auxiliary support ”  Three types of components, whose failure causes are closely related to their application scenarios.

1.1 Core Vulnerable Component Types and Functional Positioning

Although heavy-duty shelf components are small in size, they directly affect the overall load-bearing safety and thus require particular attention to the following: 6 Component type:

1.2 Main causes of wear and tear on spare parts

The wear and tear of different components are caused by “ Mechanical action ““ Environmental erosion ““ Improper operation ”  Three categories of factors dominate, with the specific corresponding relationships as follows:

• Mechanical Action Loss : Proportion 62% (Data source: "Logistics Technology and Applications") 2024  The Xth year 3  Periodically, such as wear caused by frequent removal and installation of crossbeams on safety pins, or bending deformation of shelf support beams due to overloaded cargo;
• Environmental erosion and degradation : Proportion 23% , Humid environments (such as cold-chain warehouses and food storage facilities) lead to bolt and nut corrosion, as well as oxidation of shelf boards; acidic or alkaline environments (like chemical warehouses) accelerate the aging of protective rubber feet.
• Improper handling wear and tear : Proportion 15% , a forklift operator's mistake resulted in the anti-collision skid plate being directly struck and damaged, while the pallet boards developed localized dents due to unevenly stacked goods.

1.3 Method for Identifying Failure of Wear-Prone Components

Through “ Sensory inspection +  Tool Inspection ”  By combining, you can quickly determine whether a component needs to be replaced:

• Sensory Examination : Visually inspect whether the safety pin is deformed. / Missing, is the laminate dented? /  Check for cracks and whether the foot guards are damaged; feel the bolts for rust, and ensure the support beams are not loose.
• Tool Inspection : Use a torque wrench to check the bolt tightening torque (must comply with GB/T 25800 Requirements: M12 Bolt Torque ≥45N ・ m ）、Use a level to check whether the shelf is tilted (tilt > 3° Need to replace the support beam), use calipers to measure the diameter of the safety pin (wear amount > 0.5mm Needs to be replaced).

(Shelf Accessories)

II. Core Steps for Scenario-Based Replacement of Wear Parts

The replacement procedures for different vulnerable parts vary and must be carried out according to “ Does it affect load-bearing? ““ Whether shutdown operation is required ”  Classify and execute, with the core principle being “ First, unload the load; then remove the old component; next, install the new one; finally, test for safety. ”。

2.1 Preparation Steps Before Replacement (General Procedure)

All wear parts must be replaced after completion. 3 Basic preparation to avoid operational risks:

1. Load Transfer : Use a forklift or stacker to move the goods on the shelf where the component to be replaced is located onto another rack, ensuring that the replacement area is free of any load-bearing items. (If the components being replaced are non-load-bearing parts such as column guards, a warning zone must be set up around them, prohibiting forklift traffic.)
2. Tool and Accessory Preparation : Prepare the corresponding tools based on the component type (such as torque wrenches, adjustable wrenches, or crowbars). New accessories must match the original component model exactly—for example, safety pins should align with the crossbeam hole diameter, and bolts must meet the required strength grade. 8.8 Level requirements);
3. Security Protection : Operators must wear safety helmets and non-slip gloves. When replacing components at height (such as the upper beam safety pin), use a ladder for access (climbing on shelves is strictly prohibited), and ensure proper arrangements are made. 1 Personnel provide on-site supervision.

2.2 Step-by-Step Guide to Replacing Critical Wear Parts

Targeting the highest-loss frequency 4 Component-based parts, establishing standardized replacement procedures to ensure operational compliance:

2.2.1 Crossbeam safety pin replacement (most frequent, accounting for the highest proportion of wear-part replacements) 35% ）

1. After confirming that the corresponding beam is free of cargo, gently pry out the old safety pin using a crowbar. (If it’s rusted and stuck tight, you can first apply a small amount of rust remover and let it sit for a moment.) 5 Minutes);
2. Remove the old safety pin and use a cloth to clean out any dust or rust from the beam pin hole.
3. Align the new safety pin with the pin hole, and gently tap it until fully seated (making sure both ends of the safety pin protrude beyond the outer side of the crossbeam). ≥5mm );
4. Shake the beam with your hands to check whether the safety pin is securely fastened, ensuring there are no loose or unusual noises.

2.2.2 Laminated support beam replacement (critical for load-bearing; replacement volume accounts for 28% ）

1. Transfer all goods onto the transfer pallet, and remove the self-tapping screws connecting the pallet to the support beams (using an electric screwdriver will be more efficient and help prevent stripped threads).
2. The two worked together to lift the old shelf board (each board weighs less than... ≥20kg (Requires two-person operation), exposing the support beam below;
3. Use a wrench to unscrew the connecting bolts at both ends of the support beam and the upright posts, then remove the old support beam.
4. Place the new support beam, align it with the column bolt holes, and first pre-tighten the bolts (without fully tightening them). Then, adjust the horizontal level of the support beam—use a level to ensure accuracy, keeping the error within the specified tolerance. ≤1° );
5. Tighten the bolts in diagonal order (torque meets requirements: M10 Bolt ≥30N ・ m ), reattach the shelf and secure it with screws.

2.2.3 Column crash protection foot replacement (most rapidly worn, with replacement volume accounting for 22% ）

1. Set up warning tape around the foot protection area to prohibit forklifts from approaching;
2. Use a screwdriver to remove the expansion screws connecting the old skirting board to the upright post (if the screws are stripped, a broken screw extractor can be used).
3. Clean the adhesive or dirt from the column surface, then compare it with the new skirting board dimensions (which must match the column's cross-section, e.g., 100×100mm Column supports with matching kick plates;
4. Attach the new foot guard and use an impact drill to create holes (the hole diameter must match the expansion screws, and the depth should be carefully controlled). ≥60mm ), insert the expansion screw and tighten it;
5. Pat the foot guard with your hand to check if it’s secure and free from any wobbling.

2.2.4 Replace connecting bolts and nuts (rust prevention is critical; the replacement quantity accounts for 15% ）

1. Use a torque wrench to check the torque of the old bolts and confirm whether rust has caused insufficient torque (below the standard value). 70% To be replaced);
2. Use a wrench to unscrew the old bolts and nuts. If the nuts are rusted, you can use a socket wrench combined with an extension bar (but avoid applying excessive force to prevent damage to the column's threaded holes).
3. Use a wire brush to clean the rust from the bolt holes in the columns, and apply a small amount of anti-rust grease (to extend the lifespan of new bolts).
4. Install new bolts and nuts (must meet the original strength grade, e.g., 8.8 High-strength bolts of Grade X, tightened to the standard torque using a torque wrench. M12 Bolt ≥45N ・ m ， M10 Bolt ≥30N ・ m );
5. Apply anti-rust paint to the bolt heads and mark them clearly (for easy inspection and traceability next time).

2.3 Safety Operating Procedures for Replacement Process (Avoid Accidents—Must Be Strictly Followed)

• Do not replace load-bearing components (such as support beams or bolts) while the shelf is under load, according to the 2024 "Annual Shelf Safety Operation and Maintenance Report"—incidents caused by such improper operations account for a significant portion. 47%；
• When working at heights, the ladder must be placed on a level surface, with non-slip pads at the ladder feet. Operators are prohibited from standing on the top step of the ladder. 2 At or above the specified level;
• The replaced old components must be stored separately; recyclable parts (such as steel materials) should be handed over to professional organizations for proper handling—discarding them at random is strictly prohibited.
• The replacement process must be properly documented by completing the "Shelf Component Replacement Record Form" (including the replacement date, component type, replacement quantity, operator, and acceptance results).

(Shelf Accessories)

III. Acceptance Criteria After Replacement and Daily Maintenance Strategies

Completing the replacement doesn’t mean the process is over—strict acceptance checks are still required to ensure safety, while also establishing a daily maintenance mechanism to minimize future wear and tear.

3.1 Acceptance Criteria for Replacing Wear Parts

According to GB/T 25800 "General Technical Specifications for Storage Racks"—after replacement, it must be “ Stability ““ Functional ““ Security ”  Three-party acceptance:

3.2 Daily maintenance strategies (reducing replacement frequency, extending component lifespan)

1. Regular check-ups : Develop a "Shelf Maintenance Schedule," such as weekly inspections of safety pins. 1 Second, bolts should be inspected monthly. 1  Second, inspect the foot protection equipment quarterly. 1  Next, address any issues promptly;
2. Environmental Protection : In humid environments, moisture-proof pads should be installed at the bottom of the shelves, and rust-preventive paint should be sprayed regularly (once a year). 1 Second); the chemical warehouse must use corrosion-resistant material components (such as stainless steel bolts, PVC Foot protection);
3. Operation Training : Conduct training for forklift operators to prevent collisions with shelves (optional: install infrared sensing warning devices at the foot guards to reduce the likelihood of impacts).
4. Load Management : Strictly adhere to the shelf's rated load capacity—overloading is strictly prohibited (as overloading accelerates the wear and tear of the supporting beams). 3 Twice, data source: Hagerlis Shelf Operations Manual).

3.3 Maintenance Effectiveness Data Reference

A certain e-commerce logistics warehouse, by implementing the aforementioned maintenance strategy, has reduced its annual replacement volume of vulnerable parts to 2022 Year's 1200  The number drops to 2024  Year's 580  Case, declining 51.7% ; Shelf safety accident rate from 0.8% Drop to 0.1% , maintenance costs saved by an average of per year 18  Ten thousand yuan (Data source: This warehouse) 2024  Annual Operations and Maintenance Report).

Conclusion

Replacing heavy-duty shelf wear parts may be a basic operation, but it directly impacts warehouse safety and operational efficiency. Companies need to ensure this is done carefully and promptly. “ Accurately identify worn components, strictly follow replacement procedures, and strengthen after-sales acceptance and maintenance. ”  Full-process management will standardize and streamline the work of component replacement. In the future, with the application of intelligent monitoring technologies—such as IoT sensors that provide real-time monitoring of component wear—replacing vulnerable parts will move from “ Regular replacement ”  Shift to “ Replace on demand ” , further enhancing shelf operation efficiency and reducing safety risks. For warehouse managers, paying close attention to the details of component replacement is crucial for building a solid foundation of safe operations for the enterprise. “ The First Line of Defense ”。