Forklift Damage to Steel Columns: What to Do (And What Not to Do)
- Aaron Mandel
- Jan 13
- 2 min read
Forklifts are essential in warehouses and distribution centers—but they’re also one of the most common causes of structural steel damage. A single impact to a steel column can compromise the integrity of an entire structure if it’s not handled correctly.
At Structural Welders, we’re called in regularly across New York, New Jersey, and Connecticut to assess and repair forklift-damaged steel columns. Here’s exactly what you need to know when it happens.
Why Forklift Damage Is More Serious Than It Looks
Even a “minor” hit can cause:
Hidden cracks in welds
Bent flanges or buckled steel
Loss of load-bearing capacity
Progressive failure over time
Steel columns are designed to carry vertical loads. When they’re struck sideways, the stress paths change—and that’s when problems begin.
First: What You SHOULD Do Immediately
If a forklift hits a steel column:
Stop Operations Near the Area
Continuing to load or move inventory can worsen the damage.
Visually Inspect the Column
Look for dents, cracks, twisting, or separation at welds and base plates.
Document the Damage
Take photos from multiple angles for internal records and insurance.
Call a Structural Welding Professional
This is not a cosmetic issue. It’s a structural one.
What You Should NOT Do
These mistakes are extremely common—and dangerous:
❌ Ignore the damage because “it still looks straight”
❌ Grind it smooth and paint over it
❌ Weld without assessing load paths
❌ Add makeshift braces without engineering consideration
Covering damage does not restore strength.
How Forklift-Damaged Columns Are Properly Repaired
Every repair depends on severity, but professional solutions typically include:
Structural welding of cracked areas
Reinforcement plates or sleeves
Gussets to redistribute loads
Partial column replacement if needed
Temporary shoring if required for safety
The goal is not just to fix the visible damage—but to restore structural capacity.
Case Example
A warehouse in Rockland County, NY experienced repeated forklift impacts on a steel column near a loading zone.
Our team:
Assessed the column under load
Welded reinforcement plates
Added steel guards to prevent future impact
The column passed inspection and the facility avoided shutdown.
Preventing Future Forklift Damage
After repairs, we often recommend:
Steel column guards
Bollards or barriers
Adjusted traffic flow
Operator awareness training
Prevention costs far less than emergency repairs.
Why Structural Welders
Experience with active warehouses
On-site mobile welding
Structural—not cosmetic—repairs
Clear communication with managers and inspectors
We understand how warehouses operate and work around your schedule.
Concerned About a Damaged Column?
If a forklift has struck a steel column in your facility, don’t wait.
📞 Call Structural Welders: 844-9-WELDER (844-993-5337)
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