Pallet racking holds tonnes of stock above people's heads, and most racking damage comes from everyday knocks by forklifts. A bent upright that looks minor can seriously reduce the strength of a whole bay. That is why UK guidance sets out a layered inspection routine rather than a single annual check.
What does UK guidance say about racking inspections?
Pallet racking is work equipment, so PUWER applies. The detailed guidance comes from HSE's HSG76 Warehousing and storage: a guide to health and safety and from SEMA, the Storage Equipment Manufacturers' Association. Following HSG76 and SEMA is not strictly a legal requirement in itself, but they are what an inspector or court would expect a responsible business to follow - so ignoring them is hard to defend after an accident.
The guidance recommends three levels of checking:
- Immediate reporting - staff report any damage or collisions as soon as they happen, with a no-blame culture so people actually report.
- Regular visual inspections - typically weekly, carried out by a trained Person Responsible for Racking Safety (PRRS), with a written record of each check.
- Expert inspection - by a technically competent person at intervals of no more than 12 months, with a written report. A SEMA Approved Rack Inspector (SARI) meets this standard.
How often is right for your warehouse?
Weekly is the common starting point for busy sites. The right frequency depends on risk: forklift traffic, number of operators, rack height, narrow aisles, cold store conditions and your damage history. A small store with two trucks and low turnover may justify less frequent checks; a 24-hour distribution centre may need more. Whatever you decide, write down why.
The red, amber and green damage system
SEMA guidance classifies racking damage by risk:
- Green - within acceptable limits. Record it and keep monitoring.
- Amber - damage that needs repair. It should be fixed within a set period; if it isn't, the area should be offloaded.
- Red - serious damage. Offload and isolate the area immediately and do not use it again until repaired.
Your weekly checks should record the location and category of any damage, the action taken and the date it was fixed.
What to look at on a weekly racking check
- Uprights - dents, bends, splits or twists, especially at forklift height
- Beams - deflection, damage and missing or loose locking pins
- Base plates and floor fixings - present, secure, not damaged
- Bracing - bent, damaged or missing members
- Load notices - present, legible and being followed
- Pallets - in good condition and correctly placed, no overhang into the flue space
- Anti-collapse mesh and end-of-aisle barriers - intact
Making sure the whole aisle actually gets checked
The biggest weakness of a racking check is the person who stands at the end of an aisle and glances down it. Damage at the far end, or on the back face of a run, simply gets missed.
Checkmate's circuit checks solve this. Tags are fitted along the racking - for example at each end of each aisle - and linked into a circuit. To complete the check, the inspector has to walk to every tag in turn, down one aisle and back up the next. Each stage is time-stamped, defects can be photographed on the spot, and the finished report is stored automatically for your annual inspector, your insurer or HSE.
Frequently asked questions
How often should pallet racking be inspected in the UK?
HSG76 and SEMA recommend weekly visual inspections by a trained Person Responsible for Racking Safety, plus an expert inspection at least every 12 months, with immediate reporting of any damage in between.
Is a racking inspection a legal requirement?
Racking is work equipment under PUWER, which requires it to be maintained and inspected where deterioration could cause danger. HSG76 and SEMA set out the accepted way of doing this.
Who can carry out a racking inspection?
Weekly checks can be done by a trained member of staff (the PRRS). The annual inspection should be done by a technically competent person, such as a SEMA Approved Rack Inspector (SARI).
What does red damage mean on racking?
Red is serious damage. The affected area should be offloaded and isolated immediately and not used until it has been repaired.