A forklift collision with a racking upright is the most common type of damage in warehouses. The decision to repair or replace the entire frame depends on the extent of the deformation — and making the right call is safety-critical.
When to Repair and When to Replace
Per damage tolerances from the Dexion P90 manual, which are applicable as a general benchmark: upright bend in the beam direction must not exceed 5 mm per 1000 mm, in the bracing direction 3 mm per 1000 mm. Diagonal (bracing) bend up to 10 mm per 1000 mm. Permanent beam deflection greater than SPAN/800 means replacement. Under the EN 15635 traffic-light system, an upright bend of 10 mm/m or more is a red classification — immediately unload the section and cordon it off.
Repair using a manufacturer-supplied splice kit is possible where the bend is localised without weld damage and the base plate and bracing are intact. In all other cases — cracked weld, flattened profile, both uprights damaged, torn-off base plate — full frame replacement is required. If in doubt, replace.
Never weld a damaged upright. The heat-affected zone alters the mechanical properties of the steel and the frame no longer complies with the type test per EN 15512. All manufacturers explicitly prohibit this in their installation manuals.
Profile Compatibility
Frames from different manufacturers are not interchangeable. The upright profile, perforation pitch and slot geometry are proprietary. Jungheinrich uses a C-profile with CKD frames and three different diagonal lengths. SSI Schäfer has a proprietary profile. Dexion offers the P75 to P140 range with Speedlock slots at 50 mm pitch. Mecalux supplies pre-assembled frames with their own profile. Stow uses a specific P-slot (butterfly) perforation. HEMECO has a C-profile with increased rigidity and square holes.
Even within a single manufacturer, different generations exist — before ordering, verify the type from the rating plate or project documentation. Stow beams will not fit Dexion uprights and vice versa, even if the perforation pitch looks similar.
Replacement Procedure
First, assess the extent of damage and identify the frame type from the rating plate. Then unload all pallets from the affected section and the lowest level of adjacent sections. For rows of more than 5 bays or heights above 8 m, secure adjacent frames with props and cordon off the work area.
Beams are removed from the highest level down, always in pairs — never leave a beam hanging from just one frame. After beam removal, release the anchors (unscrew mechanical anchors, cut chemical anchors) and remove the frame.
Erect the new frame (minimum 2 workers), check verticality in two axes, and anchor with new anchors into new holes — always. Tightening torques vary by manufacturer: Jungheinrich 60 Nm, WDX 50 Nm, Stow 35-54 Nm, Mecalux 35 Nm, Dexion 22 Nm. Beams are fitted from the lowest level up, in pairs, with a locking pin at both ends of every beam. Finish with before/after photo documentation and a report recording the date, old and new frame types, and anchor types.
Damage Prevention
Protective column guards at the base of uprights absorb forklift impacts — anchored with 4x M12 bolts into the floor. Protective bollards in front of row ends and guide rails in aisles reduce the risk of direct contact. Equally important is a culture of reporting — every impact must be documented without fear of reprisal. Regular inspections per EN 15635 catch damage early, before amber turns red.
FAQ
Can you replace just one upright instead of the full frame?
For minor damage, yes — using a manufacturer-supplied repair splice. In most cases, replacing the full frame is faster and safer.
Is a structural recalculation needed?
Not if you are replacing with an identical frame. Recalculation per EN 15512 is required when the configuration changes — different height, different number of levels, or a change in loading.
JTB STORAGE carries out frame replacements and racking inspections for all major manufacturers. We work with Jungheinrich, SSI Schäfer, Dexion, Mecalux, Stow, BITO, HEMECO and others. Contact us.