Nationwide Coverage for Racking Inspections by our SEMA Approved Racking Inspectors - email us on sales@a-zrackinspections.co.uk

Common Types of Racking Damage – Pallet & Cantilever Systems

Identify & Prevent Warehouse Racking Damage with SEMA Approved Racking Inspectors

Racking damage is one of the leading causes of warehouse accidents, stock loss, and costly downtime. Whether it's pallet racking or cantilever systems, early detection through professional racking inspections is essential. At A-Z Rack Inspections Ltd, our SEMA Approved Racking Inspectors (SARIs) regularly identify and classify damage using the SEMA RAG system (Red/Amber/Green) to help businesses stay compliant with HSE, PUWER, HSG76, and SEMA guidelines. Below are the most common types of racking damage we encounter across the UK – from North Wales (Mold, Flintshire) to Manchester, Liverpool, Birmingham, Cardiff, and nationwide.

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Pallet racking (adjustable pallet racking / APR) is the most widely used system in UK warehouses. The following damage types are frequently found during our annual inspections:

Most Common Pallet Racking Damage Types

Upright Frame Damage – Bent, twisted, or buckled uprights from forklift impacts or overloading. Even minor bends can reduce load capacity dramatically.
Beam Deflection & Damage – Sagging, bowing, or cracked beams caused by overloading, pallet overhang, or impact. Common in high-turnover retail/logistics warehouses.
Bracing & Diagonal Damage – Bent, missing, or detached bracing reduces frame stability. Critical for seismic/load resistance.

Baseplate & Floor Fixing Issues – Loose, missing, or corroded anchor bolts and baseplates – especially in older or outdoor installations. Can cause entire bay instability.
Safety Clip / Locking Pin Failure – Missing or damaged beam safety locks, allowing beams to dislodge under load.
Load Notice & Signage Missing – No visible safe working load (SWL) plaques – a legal compliance failure under PUWER.

Most Common Types of Cantilever Racking Damage

Cantilever racking is designed for long, bulky items (timber, steel, pipes). Its open-front design makes it more exposed to certain damage:

Most Common Cantilever Racking Damage Types

Arm Deflection & Bending – Most frequent issue – arms bend downward/upwards or twisted from overloading or impact.
Column Lean / Twist – Uprights lean or twist from forklift strikes or uneven loading. Critical stability risk.
Bracing & Connection Damage – Loose or bent bracing, cracked welds at arm-column joints.

Baseplate & Anchor Failure – Corrosion, loose bolts, or inadequate fixings – especially in outdoor yards.
Arm End-Stop / Stopper Damage – Missing or damaged end stops allowing loads to slide off.
Overhang & Load Placement Issues – Incorrect loading causing imbalance and arm stress.

SEMA RAG Damage Classification Explained

Understanding the SEMA RAG System for Racking Damage

The SEMA RAG system is the industry-standard method for classifying racking damage risk:

Red – Immediate danger: Unload and isolate bay immediately. High risk of collapse.
Amber – Serious risk: Repair within 4 weeks; no reload once bay is empty.
Green – Minor or no immediate risk: Monitor and record; repair at next opportunity.

Our SEMA Approved Racking Inspectors apply RAG accurately during every inspection, providing clear photographic evidence and prioritised recommendations.

Concerned About Racking Damage? Get Expert Help

Contact our SEMA Approved Inspectors for a free quote on damage assessment and inspection.

Phone: 07917 664940 | 07947 886161 Email: sales@a-zrackinspections.co.uk