Repair & Maintenance
Damaged Rack Doesn't Have to Mean Downtime or a Full Replacement
We assess damage on-site, source the right components, and repair your system to original load specs, so you can get the bay back in service without replacing a system that doesn't need it.
Warehouse rack repair and maintenance involves replacing or reinforcing damaged racking components such as uprights, beams, base plates, and anchors to restore structural integrity and OSHA compliance. Preventive maintenance programs include regular inspections, hardware tightening, and documentation of load capacity changes.
The Challenge
Forklift Damage Is Inevitable. What You Do Next Determines the Risk.
In any active warehouse, uprights get struck, beams get knocked, and connectors loosen over time. The problem isn't that it happens. It's what facilities do about it. Red-tagging a bay and leaving it is a temporary fix. Replacing the whole system is often unnecessary. And doing nothing is how a single forklift strike becomes a structural failure three months later. OSHA requires prompt repair of damaged racking. Continuing to use damaged systems despite known hazards establishes willful negligence in accident investigations.
We respond fast, assess the actual damage, and repair what needs repairing, without overselling a replacement when a repair will do.
What You Get
Everything Included, No Surprises
On-Site Damage Assessment
We schedule an on-site visit as quickly as possible, often within a few days for local jobs. We inspect the damaged components (and adjacent structure, anchor integrity, and secondary damage) and give you an honest written assessment of what can be repaired versus what needs replacement.
Component Repair & Replacement
We repair or replace damaged uprights, beams, connectors, anchors, and base plates using OEM or manufacturer-equivalent components sourced from our relationships with all major rack brands. Every repair is load-verified before the bay returns to service. Single upright replacement typically runs $800–2,000 installed; beams $100–400.
Preventive Maintenance Programs
Beyond reactive repairs, we offer quarterly and annual maintenance programs: comprehensive inspections, bolt tightening, safety component replacement, lubrication of dynamic systems, and on-the-spot minor repairs. Well-maintained racking systems last 20–30 years. Neglected ones don't.
How It Works
A Clear Process, Start to Finish
Service Request & Response
Contact us about the damage. We'll gather basic information about your system and schedule an on-site visit. Response times depend on location and crew availability, but we prioritize urgent situations and move quickly.
On-Site Damage Assessment
We inspect the damage in context, not just the struck component, but adjacent structure, anchor integrity, and any secondary damage that might not be immediately visible. You get an honest written assessment with photos before any repair work is quoted.
Component Sourcing
We source manufacturer-compatible replacement components through our relationships with Interlake Mecalux, Ridg-U-Rak, Frazier, Steel King, Speedrack, and others. For discontinued systems, we explore used/surplus markets or coordinate custom fabrication. In 25+ years, we've always found solutions.
Repair & Installation
Our team performs the repair on-site (upright replacement, beam swap, anchor reset, bracing repair, or whatever the assessment requires) using proper shoring and load transfer techniques so adjacent sections stay in service. Most repairs are completed section-by-section, maintaining 80–90% warehouse capacity.
Load Verification & Documentation
After repair, we verify the system meets its original load ratings, photograph the completed work, and provide a written repair report. Significant structural repairs are PE-certified where required by your jurisdiction. All documentation is ready for OSHA, insurance, and your maintenance records.
Scope of Work
Installations We Handle
Drive-In & Drive-Through Systems
High-density systems require specialized repair expertise. We replace damaged rail beams maintaining proper track alignment, repair guide rails and load spacers, and address structural damage from fork truck impacts within lanes. Drive-in repairs must be precise, and we have the experience to do them right.
Push-Back & Pallet Flow Repairs
Dynamic racking involves mechanical components requiring maintenance beyond structural repairs. We replace carts, wheels, and track components, adjust flow rates and brake systems, and repair or replace damaged lanes. Our technicians are factory-trained on major dynamic system brands.
Multi-Tier & Mezzanine Repairs
Elevated structures require careful repair planning. We repair deck surfaces and support systems, replace handrails and safety gates, address structural damage to support columns, and maintain stairs and access components. Safety is paramount when working on elevated platforms.
Cantilever Rack Repairs
Long-span cantilever systems experience unique stresses. We replace damaged arms maintaining proper engagement, repair base and bracing connections, address deformation from overloading, and verify capacity for actual loading. When components are hard to find, we coordinate sourcing directly with original manufacturers.
The Difference
Why Facilities Teams Choose Hammerhead
Emergency & Priority Repairs
A red-tagged bay is lost capacity, and lost capacity costs money. We prioritize urgent repairs and work to get a crew to your facility as quickly as scheduling and geography allow. After-hours and weekend response is available when operational continuity is at stake.
Honest Repair vs. Replace Assessment
We tell you what needs replacing and what can be repaired, not what's most profitable for us. Isolated damage to a few components with readily available parts? Repair it. Widespread damage across multiple sections approaching 60–70% of replacement cost, or a system that no longer meets current codes? We'll tell you that too, with cost comparisons for both paths so you can make an informed decision.
OEM & Compatible Components
We maintain relationships with all major racking manufacturers, allowing us to source exact-match OEM components that preserve system integrity and warranties. For discontinued product lines, we identify suitable alternatives meeting or exceeding original specifications, or source certified used components at 40–60% less than new.
Documented Repair Records
Every repair comes with written documentation: what was damaged, what was replaced, photos before and after, and confirmation that the system meets original load ratings. Critical for OSHA compliance, insurance claims, and property transactions.
Common Questions
Frequently Asked Questions
How quickly can you respond to emergency repairs?
We prioritize emergency situations and schedule crews as quickly as possible. For local jobs, that can mean a visit within a day or two. For facilities farther from our teams, we coordinate travel and logistics to minimize downtime. Initial response includes damage assessment, safety measures, and temporary shoring where needed. Permanent repairs follow once components are sourced.
Can we keep using damaged racks while repairs are scheduled?
It depends on damage severity. Minor damage (green or yellow rated) may be safe with reduced capacity until repairs are scheduled. Orange-rated damage requires immediate capacity reduction and close monitoring. Red-rated damage requires offloading the section immediately. Continued use creates unacceptable risk and OSHA violations. Our assessors give specific guidance on each situation.
Do you provide warranties on repair work?
Yes. All Hammerhead repairs include a one-year workmanship warranty covering installation quality and component fit. Replacement components carry manufacturer warranties (typically 1–5 years). We stand behind our work and return to address any warranty issues at no cost.
What if you can't find matching components for our system?
Our extensive supplier network locates even obscure components. For discontinued systems, we explore used and surplus markets, investigate compatible alternatives from other manufacturers, or coordinate custom fabrication with engineering certification. In 25+ years, we've always found a solution.
How much do typical repairs cost?
Costs vary by damage extent and component needs. Single upright replacement typically runs $800–2,000 installed. Beam replacements cost $100–400 per beam. Comprehensive maintenance programs start around $2,000–5,000 annually depending on facility size. We provide free estimates with exact costs before any work begins.
Repair vs. Replace
When to Repair, and When to Replace
Repair Makes Sense When…
Damage is isolated to a few components while the overall system is structurally sound. Replacement parts are readily available at reasonable cost. The current system configuration meets your operational needs. The remaining useful system life justifies the repair investment. In these cases, repair is nearly always the faster, cheaper, and smarter path.
Replacement Makes Sense When…
Damage is widespread across multiple sections. The system is obsolete or discontinued and components are unavailable. Current capacity is no longer adequate for your growing operation. Repair costs approach 60–70% of full replacement cost. The system doesn't meet current codes (seismic, fire, ANSI MH16.1). We provide side-by-side cost comparisons so you make the call based on numbers, not guesswork.
Component Sourcing: OEM, Used & Custom
We maintain direct relationships with Interlake Mecalux, Ridg-U-Rak, Frazier, Steel King, Speedrack, Konstant, and others, allowing us to source exact-match OEM components that preserve system integrity and warranties. For discontinued systems, we access used/surplus markets at 40–60% less than new, or coordinate custom fabrication with engineering certification when no other option exists.
When a rack gets hit, the clock starts ticking. Every hour that bay is down is lost capacity. We stock common parts and prioritize getting crews on-site fast so our clients can get back to full operations without a long wait.
Dylan Andrews
VP Operations, Hammerhead Warehouse Systems
Related Services
Safety Inspections
Regular inspections catch developing damage before it becomes an emergency repair, and produce the documentation your insurance carrier wants to see.
Learn More →
Installation & PM
If damage is extensive enough that a section needs to be rebuilt, our installation team handles full teardown and reinstallation.
Learn More →
Design & Layout
Recurring damage in the same area may signal a layout issue: tight aisles, bad turning radii, or high-traffic zones that need redesigning.
Learn More →Got a Damaged Rack? Let's Take a Look.
Send us a photo or give us a call. We'll schedule a free on-site assessment and get your bay back in service. No obligation to proceed with repairs.
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