Why do I need regular pallet racking inspections?

On the face of it, your storage and racking systems may appear to be perfectly safe and stable.

However, every day warehouse operations can cause wear and tear through constant use. Minor bumps or scrapes from forklifts, hand trucks and other vehicles and occasional accidental (or sometimes negligent) overloading can all increase the stress on your racking systems.

These factors may ultimately render your pallet racking systems unsafe because they can affect both structural integrity and load-bearing capacity.

What are my legal responsibilities?

Under the Health & Safety at Work Act 1974 and The Provision & Use of Work Equipment Regulations (PUWER) every employer has the responsibility to ensure a safe place of work for their employees. It follows, therefore, that employers will be held liable in the event of accidents.

As far as a warehouse environment is concerned, this means ensuring that your racking and storage systems are in a safe condition.

Because of the nature of warehouse operations, single incidents can affect the integrity of racking structures, sometimes on a daily basis. For this reason, regular racking inspections by an approved person are mandatory under PUWER.

What are the risks of going without racking inspections?

Damaged or unsafe racking presents a significant risk. A first or even second time impact or overload may not give rise to a collapse, but increased strain, in particular on load-bearing areas of a racking system, means that eventually the risk of failure is high.

Employers are responsible for warehouse safety, so should consider all the possible impacts of accidents such as a racking system collapse:

• Normal warehouse operations will be disrupted
• Business productivity – and profitability – will be affected
• Products may be damaged or written off
• In severe cases, injury or loss of life can occur
• Costs can include heavy fines, compensation claims and legal expenses
• Prison sentences can be handed out in the worst cases
• Your firm could go out of business as a result of the above

What should I do if I suspect my racking may be damaged?

If you feel that your racking systems may be damaged or at risk, you need to order an immediate racking inspection to be carried out by a suitably experienced, skilled and independent expert.

In cases of severe risk, you are advised to seal off affected areas until they can be declared safe.

What should I look for in a racking inspection supplier?

You need to be confident that your racking inspection supplier is experienced with multiple types of warehouse operations and environments, and with the different systems of the various pallet racking manufacturers.

Good inspectors will use original, manufacturer-supplied design manuals and loading charts to assess your racking. They will also understand the levels of racking damage tolerance, be able to verify that your racking meets the required standard and is being operated within its design capacity.

How regularly do I need a racking inspection?

Racking damage can occur at any time, so warehouse procedures should include processes for a) preventing damage and b) reporting it as soon as it occurs to a responsible person.

The PUWER regulations state that inspections must be undertaken on a “regular” basis by a competent person.

What this means in practice is that employers must decide for themselves, or with the advice of a warehouse safety specialist, the frequency of inspections required given the level and type of activity in the warehouse. Usage and impact patterns can be built up over time in order to arrive at a decision about the required frequency.

Some warehouse environments require only a routine annual survey and racking inspection by a qualified inspector. Other warehouses may require a formal inspection every six months, whereas faster moving or busier warehouses will need a weekly or even daily inspection by a suitably trained individual or team.

What is involved in a racking inspection?

Acorn Warehouse Solutions provides a warehouse and racking inspection service to ensure your racking infrastructure is operating to its intended purpose, within design specifications and, above all, safely.

Our Racking Inspectors can assess all types of racking from adjustable pallet racking to drive in/drive through racking and narrow aisle high bay racking.

Our inspections include a list of specific checks and tests to ensure that your racking complies with workplace health and safety requirements, and incorporate visual and operational assessments of:

• Racking uprights and floor fixings
• Beams and beam end connectors
• Frame bracing structures
• Column guards
• Safety and loading notices

Depending on the outcome or your racking section, your Inspection Report may include:

• A description of the areas assessed
• Any defects identified along with their severity and possible impact
• An indication of any damaged infrastructure along with a location map
• Recommendations on remedial action
• Advice and guidance on racking maintenance

How should I look after my racking systems myself?

The key to safe warehouse operations is minimising risk. As well as ensuring that all your racking systems are regularly inspected, all employees should be given instruction on the safe operation of equipment. Provision should also be made for all necessary health and safety precautions.

With racking systems, particular attention should be paid to preventing:

• Damage by fork lift trucks
• Damage by over-loading
• Overloading, particularly following changes to the quantity and height of beam levels
• Incorrect design or installation