The Importance of Racking Inspections: Protecting Your Warehouse, Staff, and Stock
The Importance of Racking Inspections: Protecting Your Warehouse, Staff, and Stock
In today’s fast-paced logistics and warehousing industry, pallet racking systems are essential for storing and organising large volumes of goods. They are the backbone of modern warehouse efficiency, enabling businesses to maximise space, streamline workflows, and keep up with customer demand.
But despite their strength, pallet racking systems are not indestructible. They are exposed to daily wear and tear, forklift traffic, overloading, and environmental conditions that can gradually compromise their integrity. Left unchecked, this can lead to dangerous failures, stock loss, and serious accidents.
That’s why regular racking inspections are not just a best practice — they are a legal and safety requirement. At A-Z Rack Inspections Ltd, our specialist team of SEMA Approved Racking Inspectors (SARI) provide professional inspection services across the UK, ensuring your warehouse remains safe, compliant, and fully operational.
Why Racking Inspections Are Essential
1. Protecting Warehouse Safety
The single biggest reason for carrying out racking inspections is safety. Racking collapse incidents can cause devastating injuries or even fatalities. A properly inspected racking system helps safeguard staff, visitors, and contractors working in your warehouse.
2. Preventing Product Loss
One accident can destroy thousands of pounds’ worth of stock. Regular inspections ensure weak points are spotted early, preventing stock damage before it becomes costly.
3. Reducing Downtime
When racking fails, entire sections of a warehouse may need to be closed off. Inspections keep operations running smoothly by preventing breakdowns that disrupt supply chains.
4. Compliance with UK Health & Safety Regulations
Failing to comply with HSE requirements (HSG76) or PUWER (Provision and Use of Work Equipment Regulations 1998) can lead to enforcement action, fines, and prosecution. Inspections give you proof of compliance and peace of mind.
5. Extending the Lifespan of Racking
By catching small issues before they escalate, inspections extend the service life of your racking systems, saving money on replacements and repairs.
UK Legal Requirements for Racking Inspections
Under HSE’s HSG76 guidance, warehouse operators must ensure that all racking systems are:
Installed correctly and safely
Maintained in good working condition
Inspected regularly by competent individuals
Additionally, PUWER (1998) classifies pallet racking as work equipment, which means it must be:
Suitable for its intended use
Maintained in a safe condition
Inspected periodically by a competent person
This is why the SEMA Approved Racking Inspector (SARI) qualification is so important. SARI inspectors are trained to the highest industry standard, ensuring inspections are thorough, compliant, and reliable.
The A-Z Rack Inspections Approach
At A-Z Rack Inspections, our service goes beyond a quick visual check. We provide a comprehensive inspection process designed to meet the unique needs of your warehouse.
Our inspections include:
Full structural assessment of racking frames, beams, bracing, fixings, and safety locks
Identification of damage caused by forklifts, overloading, or environmental conditions
Risk categorisation following SEMA’s traffic-light system:
Green Risk – safe for continued use
Amber Risk – requires remedial action in due course
Red Risk – serious damage requiring immediate action
Written report with photographs and detailed findings
Recommendations for repairs, replacements, or protective measures
Unlike some inspection providers, we give you practical advice to keep your warehouse safe — not just a list of faults.
How Often Should Racking Be Inspected?
A layered inspection approach is the best way to maintain warehouse safety:
Daily/Weekly Checks – Carried out by your staff. These involve quick visual checks for obvious damage such as dents, missing clips, or leaning uprights.
Monthly Checks – Conducted by a nominated Person Responsible for Racking Safety (PRRS), trained to spot issues.
Annual Inspections – Carried out by a SEMA Approved Racking Inspectors (SARI) to provide a formal, independent report.
Additional inspections should also be carried out:
After any accident or impact involving racking
Following warehouse reconfiguration or racking relocation
If the racking is located in harsh environments (cold storage, outdoor yards, high-humidity areas)
Common Issues Found During Racking Inspections
Our inspectors frequently identify problems such as:
Bent or damaged uprights caused by forklift collisions
Sagging beams due to overloading
Corroded frames in damp or chilled storage environments
Loose or missing fixings and safety clips
Incorrect beam levels affecting load capacity
Unmarked load limits leading to unsafe use
Catching these issues early prevents dangerous collapses and costly repairs.
Racking Protection Measures
Prevention is always better than cure. As part of our inspection service, we also recommend racking protection systems to minimise future damage, including:
End-of-aisle barriers – Protecting vulnerable corners and run-throughs
Upright protectors and column guards – Shielding uprights from forklift collisions
Floor-mounted bollards – Preventing accidental impacts from pallet trucks
These low-cost solutions significantly reduce the risk of recurring damage.
When to Replace or Upgrade Your Racking
Even with inspections and maintenance, racking does not last forever. Signs it may be time to replace or upgrade include:
Racking over 15–20 years old with visible wear
Frequent and costly repairs in the same areas
Increased stock volumes pushing existing capacity limits
Introduction of new product types that require a different system
Structural issues such as widespread corrosion or beam deflection
In these cases, we work closely with A-Z Storage Systems to design and install modern, efficient racking systems tailored to your operational needs.
Why Choose A-Z Rack Inspections?
SEMA Approved Racking Inspectors (SARI) – Industry’s highest qualification.
Independent inspections – unbiased and professional.
Comprehensive reports – clear, practical, and compliant with HSE standards.
Nationwide coverage – inspections available across the UK.
Partner of the A-Z Storage Systems – providing seamless integration with racking supply, installation, and repair services from A-Z Storage Systems.
Conclusion
Your racking system is one of the most important investments in your warehouse. Protecting it with regular inspections is about more than compliance, it’s about protecting your people, your stock, and your business continuity.
At A-Z Rack Inspections Ltd, we provide professional, SEMA-approved inspection services that keep your warehouse safe, efficient, and compliant. Whether you operate a small distribution centre or a large-scale logistics hub, our team ensures your racking remains fit for purpose.
📞 Book your inspection today and protect your warehouse:
Call: 07917 664940 or 07947 886161
📧 Email: sales@a-zrackinspections.co.uk
