Why seismic retrofitting of racks?
Steel storage pallet racks are structural systems that are widespread across Europe’s logistics infrastructure. Their slender profiles, non-redundant connections, and the variable nature of their loading make them particularly susceptible to damage during seismic events. Unlike buildings and bridges — governed by well-established seismic design codes — rack structures have historically received limited attention in terms of seismic risk mitigation.
A large share of the existing rack stock predates current seismic guidance or was erected in regions where seismic hazard was not adequately considered at the time of design. Addressing this vulnerability through demolition and replacement is neither economically viable nor environmentally responsible. Retrofitting — enhancing the performance of existing structures through targeted interventions — offers a cost-effective and sustainable alternative.
SAVERACK builds on this premise, developing retrofitting devices and validated procedures that can be adopted by rack owners, manufacturers, and structural engineers to protect lives, reduce downtime, and extend the service life of existing warehouse infrastructure.
Project Objectives
- Develop innovative retrofitting devices for the longitudinal direction (beam-to-column connections) to enhance strength and ductility under seismic loading.
- Develop effective solutions for the cross-aisle direction (upright frames) to improve lateral stability and energy dissipation.
- Characterise device performance through dedicated experimental testing programmes, from component level to sub-assembly scale.
- Develop and validate a comprehensive numerical modelling framework for predicting the seismic response of retrofitted rack configurations.
- Conduct full-scale shake table testing to validate device performance under realistic earthquake input.
- Produce practical guidelines to assist rack owners, manufacturers, and practitioners in adopting the developed solutions.
How SAVERACK Works
Project at a Glance
| Call | RFCS-2024 (RFCS-2024-02-RPJ) |
| Proposal number | 101216407 |
| Duration | 42 months |
| Total budget | ~ €2,547,678 |
| Partners | 11 full partners + 1 associated partner (ERF) |
| Countries | 6 (Italy, Germany, Spain, Portugal, Cyprus, Romania) |
Specific Objectives
- Develop innovative rotational friction devices for beam-to-upright connections to improve seismic ductility and energy dissipation in the longitudinal direction
- Develop axial friction devices for diagonal braces in the upright frame (cross-aisle direction)
- Characterise existing racks through sub-component experimental tests on base-plate connections, beam-to-upright connections and upright frames
- Build refined numerical models calibrated on experimental results, including nonlinear dynamic analyses
- Assess seismic risk and economic losses for both standard and retrofitted rack configurations using fragility curves and loss models
- Validate the devices through full-scale shake table tests at EUCENTRE laboratories
- Develop design guidelines for practitioners and manufacturers
- Disseminate results to academic, professional and industrial communities
Work Packages
The project is structured into 8 Work Packages. For a detailed description of each WP and the responsible partner, visit the Overview page.
Expected Impact
SAVERACK’s outcomes will benefit the entire rack industry value chain — from manufacturers and installers to end-users and insurers. By reducing the seismic vulnerability of the existing rack stock, the project directly contributes to:
Safety: fewer injuries and fatalities in warehouse settings during seismic events.
Business continuity: reduced downtime and economic losses following earthquakes.
Sustainability: extended service life of existing structures, avoiding the material and energy costs of demolition and replacement.
Standardisation: practical guidelines and recommendations to inform future European standards on the seismic design and retrofitting of rack structures.