Many warehouses use racking systems to maximize storage capacity and improve organization. Too often, however, racking is installed without a full understanding of the associated safety implications. In an interview with Chuck Leon, a warehouse safety specialist with more than 35 years of experience, we explored the critical aspects of racking safety. Chuck is a recognized expert in this field. We asked him ten questions commonly raised by employers about warehouse safety, and his responses provided practical, insightful guidance toward creating a safer warehouse environment. The following is a detailed review of those responses.
1. What are the consequences of selecting incorrect racking in a warehouse?
From Chuck's perspective, choosing incorrect racking systems in a warehouse can cause a ripple effect across safety, productivity, and costs. Some of these implications include:
- Safety hazards
- Reduced storage capacity
- Lower productivity
- Product damage
- Higher operating costs
- Compliance and insurance problems
- Limited future flexibility
According to Chuck, “The bottom line is this — selecting the wrong racking system can compromise safety, efficiency, storage capacity, and profitability. Good racking design should always be considered by examining load weight, pallet size, product turnover (FIFO/LIFO), forklift type, and building dimensions.”
2. How should you go about selecting the appropriate racking for your warehouse environment?
Chuck's response is, “Selecting the right warehouse racking isn't just about fitting pallets on shelves — it affects safety, efficiency, and how easily your operations scale. A practical way to approach it is to evaluate a few key factors step by step.”
- Understand your inventory (pallet size, product dimensions, SKU variety, and turnover rates).
- Evaluate warehouse space — ceiling height, column spacing, floor load capacity, available aisle widths.
- Inventory flow (First In First Out — FIFO vs. Last In First Out — LIFO).
- Assess material handling equipment — type of lift truck, turning radius, lift height. For example, reach trucks typically allow for narrower aisles compared to standard forklifts.
- Safety compliance — ensure racking meets safety standards and regulations.
- Plan for accessibility and picking efficiency.
- Consider future growth.
- Work with a racking specialist.
“Good racking selection balances: storage density + accessibility + safety = operational efficiency.”
3. What sorts of evaluations are legally required for racking? Why?
According to the expert, “In Canada, warehouse racking systems must be evaluated to make sure they are safe, structurally sound, and compliant with occupational health and safety laws. While there isn't a single nationwide ‘Rack Law,’ several regulations and standards require inspection and engineering evaluations.”
Chuck also goes on to explain the requirements in Ontario. In Ontario there are requirements under Section 851 — Industrial Establishments, Section 7, which require Pre-Start Health and Safety Reviews to be completed for racking structures. These Pre-Start Health and Safety Reviews are required to be completed by a qualified engineer. Mr. Leon goes on to explain some of the CSA standards that apply to racking including CSA A344 — Users Guide for Steel Storage Racks. He alludes to four areas to consider:
- Engineering evaluation / certification.
- Regular rack inspections — what does your province say?
- Annual expert inspections (not a legal requirement but a best practice).
- Load capacity verification and signage.
Chuck ends by indicating, “Canadian workplaces must evaluate racking through engineering certification, routine inspections, and load capacity verification to comply with safety laws and prevent rack failure, product loss, and serious workplace injuries.”
4. How often are evaluations required and why?
Chuck says, “In Canada, warehouse racking systems should be evaluated at several different intervals to ensure they remain safe and compliant with workplace safety regulations and standards:”
- Continuous / daily visual checks.
- Regular formal inspections.
- Expert / professional evaluations.
- Additional evaluations when needed (when damage occurs, rack reconfiguration, new levels and components added).
“Daily visual checks by workers and weekly/monthly formal internal inspections, annual professional inspections, and anytime damage, modifications, or load changes.”
5. In your experience does the Ministry actually review Pre-Start Health and Safety Reviews?
The expert responded by indicating that the authorities would review Pre-Start Health and Safety Reviews. He went on to say, “In Ontario, Pre-Start Health and Safety Reviews (PSR) are required under Ontario Regulation 851 — Industrial Establishments which is enforced by inspectors from the MLTSD.”
6. Are regular racking inspections required and why? What are some key things to examine during inspections?
Chuck responded by saying that regular racking inspections are required in Canada primarily to ensure worker safety and maintain the structural integrity of warehouse racking systems. Although inspection requirements vary by province, a Canadian company with operations in multiple provinces would not be serving its employees well if it conducted inspections in one province but not in others simply because inspections are not a legal requirement everywhere.
7. Clients often ask how to determine aisle space between racking. What is the best way to go about understanding this?
This is a question many employers often ask when they are in the process of redesigning their warehouse environment as they want to maximize the use of space. According to our warehouse expert, “The best way to determine aisle space between racking is to start with the material handling equipment (MHE) that will operate in the aisles — usually forklifts. The type of truck, turning radius, and load size dictate the required aisle width. Other considerations include pallet overhang, operator safety margins, rack protector clearance, and imperfect pallet placement.”
8. What are the racking standards employers should be aware of?
Chuck provided a list of racking standards he has used throughout his career. These include the following:
- CSA A344-24 — Users Guide for Steel Storage Racks.
- ANSI MH16.1 — Specification for the Design, Testing and Utilization of Industrial Steel Storage Racks.
- ANSI MH16.2 — Standard for the Design, Testing and Utilization of Industrial Steel Storage Racks.
9. What parts of the standard have you referred to most in your career?
Chuck shared that the sections most referred to over the years were from CSA A344-24. The sections are:
- Section 7 — Capacities
- Section 8 — Inspections
These sections are essential to racking systems and keeping employees safe.
10. Tell us about one of your most memorable warehouse safety experiences. What made it so memorable?
Finally, we asked Chuck to reflect on his career. He ended by saying, “In my 35 years of working in the health and safety world I don't have one memorable moment — I think my most important thing is the clients that I have had the privilege to work with over the years. I can't tell you how many people I have trained on rack safety since 2005, but I can say it is very high. I have always said if I taught you one thing it was great, and if you learned more, even better.”
“As I start to slow down and take a moment to think about what I have done in the safety world, all I can do is smile. It is clients such as yourself that have kept me going all these years, and I just hope I made a little bit of a difference.”
Closing
Health and safety professionals like Chuck Leon continue to demonstrate a strong dedication to their field, even after many years of service. This commitment is a testament to the passion and genuine care he has for the people who work every day in warehouse environments. Thank you, Chuck, for taking the time to share your knowledge and answer important questions about warehouse safety.