Moving or altering an existing racking system

Moving or altering an existing racking system is not the same as assembling new racks. Changes to the structure, configuration or location affect the rated capacity and safety of the system. This guide explains what to consider and why manufacturer involvement matters.

When does racking need manufacturer review?

The original racking design is calculated for a specific configuration: the frame height, beam lengths, number of levels, load per level and anchoring to a particular floor. Any change that affects these factors should be reviewed by the original racking manufacturer or a competent rack designer before proceeding:

• Adding or removing beam levels: changes the load distribution on the uprights and may exceed the frame’s rated capacity
• Extending an existing row: new frames and beams must be compatible with the original system. Components from a different manufacturer or series may not fit or share the same load rating.
• Relocating to a different site: the new floor may differ in level, material or load-bearing capacity. Heights and obstructions may also differ.
• Changing the stored goods: heavier or differently shaped items may exceed the designed load or require a different beam spacing
• Replacing damaged components: replacements must match the original specification. A beam or upright that looks similar may have a different section, material or rated capacity.

What information to gather before contacting the supplier

Before requesting a review, collect:

• The existing load label or safe working load notice (photograph it)
• The manufacturer name, series name or model number from the frame or beam markings
• The current configuration: frame heights, beam lengths, number of levels, beam positions
• The proposed change: what you want to add, remove, move or alter
• Photographs of the existing installation, including any damage, modifications or missing components
• The new site details if relocating: floor plan, clear height, floor type and obstructions

Why not do it yourself?

Boltless shelving designed for hand assembly can usually be reconfigured by operators within the published instructions. Pallet racking and heavy duty systems have structural calculations behind their rated capacity. Altering them without checking the design may create an unsafe configuration that looks normal but exceeds the load limits. An overloaded or improperly modified rack may not show visible signs of distress before failure.

DOSH guidelines under Malaysia’s Occupational Safety and Health Act 1994 support manufacturer review when structural changes are made and amended safe working load notices where appropriate. Even where specific regulations do not mandate a review for the change you are making, the manufacturer is the appropriate source for confirmation that the altered system remains safe.

Dismantling and reinstallation

If a racking system is being dismantled for relocation, have the existing configuration documented before disassembly. Label components so they can be reassembled correctly. Inspect each component for damage during the process: bent uprights, deformed beam connectors, cracked welds or corroded sections should not be reinstalled.

At the new site, the installation should be treated as a new project: floor assessment, layout design, anchoring and a new load label for the installed configuration.

Frequently asked questions

Can I add shelves from one brand to another brand’s frames?

Do not assume compatibility. Beam connectors, slot patterns and material specifications differ between manufacturers and sometimes between series from the same manufacturer. Ask the supplier to confirm before mixing components.

Can I raise the top beam level to fit taller items?

Raising beam levels changes the load distribution and may require different bracing. Contact the manufacturer with the current and proposed configuration so they can confirm whether the change is within the design limits.

How do I arrange this with Hyperack?

Send photographs of the existing installation, the load label, component markings and a description of the proposed change through the contact page. For Hyperack product ranges, see heavy-duty racking, boltless rack or pallet racking. The team will advise whether a site assessment is needed and what the review involves.