Rack Safety with UpRight Warehouse Solutions: Fast Repairs, Real Prevention, and Smarter Response
Kevin chats with Dan Klinger, President and Founder of UpRight Warehouse Solutions, in this special episode of The New Warehouse Podcast’s Safety Series. The conversation centers on rack safety in warehouses—one of the most critical yet often overlooked elements of warehouse operations. UpRight Warehouse Solutions is best known for its patented UpRight Rack Repair system and proactive inspections that help facilities prevent catastrophic failures.
In the episode, Dan walks us through how his company got started, what he’s seeing in the field today, and what needs to change across the industry to truly prioritize safety. As racking becomes taller and warehouses become increasingly crowded, the margin for error becomes narrower. Dan’s message is clear: rack damage isn’t just a maintenance issue, it’s a threat to lives and livelihoods.
Complacency Is the Enemy of Safety
Warehouse racking might look sturdy, but day after day, it’s absorbing damage that too often goes unreported. According to Dan, “We have the largest physical asset standing in the room and it’s filled with the largest financial asset on the shelf… and there’s a sense of complacency.” He describes a familiar pattern: forklift strikes occur, but operators often scurry away rather than report them, and the damage accumulates, literally. It’s not about faulty engineering; Dan believes “the structures themselves are brilliantly and robustly engineered.” However, the real issue is improper usage and lack of awareness.
Dan warns that many operators don’t understand the actual danger: “People are trafficking these structures with minimal actual hands-on experience, with even less hands-on training.” The result? Every inspection reveals serious threats, including fully compromised uprights that are “defying gravity.” In short, structural damage is not rare—it’s daily business.
Rack Safety: Rapid Response vs. Dangerous Delays
Too many companies put workers at risk by trying to work around the damage rather than addressing it. But Dan’s patented Upright system changes the game. “We will fix it tomorrow if you have a PO today,” he says, highlighting the rapid turnaround UpRight Warehouse Solutions offers—sometimes under an hour once onsite. Their process includes a state-of-the-art jack system to hold up a loaded structure. At the same time, the damaged component is removed and replaced with a modular, engineered prosthetic that restores the original strength and function.
The urgency is real. Dan recalls one instance where a damaged upright, three and a half stories tall, stood unsupported while the building’s staff had to shut down multiple aisles. It was a costly but necessary move: “Which box in the aisle is worth that employee’s life?” he asks. For many operations, the answer becomes clear only after disaster strikes. UpRight Warehouse Solutions helps customers avoid that outcome by making fast and safe rack repairs possible.
Training, Culture, and the Future of Rack Safety
Equipment misuse remains the number one cause of rack damage. “Hands down, it’s the equipment and the operators on it,” Dan says. That’s why he believes better training, regular inspections, and a culture shift are essential. “The best prevention is to know what’s going on with your structures,” he adds. Guards and barriers help, but real change starts with intentional leadership.
Dan also points out a hidden risk: “I’m discouraged to share with you that 911 isn’t ready for this call.” First responders are typically not trained for large-scale racking collapses—yet another reason to be proactive, not reactive. In response, Dan and his wife, Carole, co-founded ShoreFit to create the first adapter that safely connects shoring struts to collapsed pallet racks. The product was inspired by a question raised during a recent fire chief presentation and is now part of Dan’s broader mission to make rescue and recovery safer.
Key Takeaways on Pallet Rack Safety
- UpRight Warehouse Solutions’ patented repair system operates under load, eliminating the need to unload racking first.
- Dan and team can complete rack repairs in under an hour, even while the structure is still under load, minimizing disruption and downtime.
- Rapid repair reduces the risk of collapse, downtime, and injury.
- Regular inspections and a proactive safety culture are non-negotiables.
- The leading cause of rack damage is equipment strikes by forklift operators, not natural disasters or structural design flaws.
- ShoreFit’s new adapter enables first responders to stabilize collapsed pallet racks more quickly and safely during rescue operations.
Listen to the episode and leave your thoughts in the comments.
Guest Information
For more information on UpRight Warehouse Solutions, click here.
To follow UpRight Warehouse Solutions on LinkedIn, click here.
