Top 10 Racking and Shelving Damage to Look Out For!

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Top 10 Racking and Shelving Damage to Look Out For!

Warehouse racking systems are built to handle heavy loads and demanding operations, yet they often face neglect in routine maintenance. Unlike forklifts or other warehouse machinery, racking systems typically lack scheduled maintenance plans, which means damage can go unnoticed. Ignoring these issues compromises safety, increases the risk of racking collapses, and can lead to costly downtime.

By following SEMA (Storage Equipment Manufacturers’ Association) guidelines and conducting regular racking inspections, businesses can identify risks early and maintain compliance with UK warehouse safety regulations. Below are the top 10 most common types of racking and shelving damage—along with practical prevention strategies.

1. Upright Damage

Uprights form the vertical support structure of pallet racking systems, and they are highly vulnerable to forklift collisions. Even minor impacts can weaken structural integrity, increasing the risk of racking failure.

Prevention Tips:

✔️ Ensure only certified forklift operators handle warehouse equipment
✔️ Maintain clear aisle space to reduce the likelihood of collisions
✔️ Install column guards, corner guards, and bollards for extra protection
✔️ Conduct routine inspections, especially after any impact

2. Damaged Bracing

Bracing connects uprights and helps maintain racking stability. Overloading, forklift contact, or general wear can cause bent or broken braces, compromising the structure.

Prevention Tips:

✔️ Adhere to manufacturer load capacity guidelines
✔️ Inspect bracing for bends, cracks, or loose connections
✔️ Replace damaged braces immediately to prevent structural weakness

3. Beam Damage

Beams provide horizontal support and bear the weight of stored inventory. Any bending, denting, or connection failure can reduce load capacity and increase the risk of collapse.

Prevention Tips:

✔️ Evenly distribute weight to avoid excessive pressure on specific beams
✔️ Check for beam deflection and ensure beams are securely locked
✔️ Replace damaged beams instead of attempting makeshift repairs

4. Loose or Damaged Baseplates

Baseplates anchor racking to the warehouse floor and keep structures stable. If they become loose or damaged, the entire system’s integrity is at risk.

Prevention Tips:

✔️ Ensure baseplates are securely bolted to the floor
✔️ Inspect for signs of loosening, rust, or impact damage
✔️ Conduct routine checks, especially after heavy warehouse activity

5. Cracks in Material or Welded Connections

Structural cracks, especially in beam-to-upright connections, can compromise weight-bearing capacity and pose serious safety risks.

Prevention Tips:

✔️ Unload damaged areas immediately to prevent further stress
✔️ Follow manufacturer recommendations for component replacements
✔️ Avoid attempting on-site welding repairs, as it can weaken the steel

6. Overloading Racking Systems

Overloading is a leading cause of racking failures. When a system is pushed beyond its intended weight capacity, it can lead to beam deflection, upright buckling, or complete collapse.

Prevention Tips:

✔️ Clearly display rack load capacities in all storage areas
✔️ Train staff on proper pallet positioning and weight distribution
✔️ Regularly review load compliance to avoid exceeding weight limits

7. Missing or Damaged Safety Locking Pins

Locking pins secure beams to uprights, preventing them from dislodging due to movement or impacts. If these small but critical components are missing or broken, racks become unstable.

Prevention Tips:

✔️ Inspect beams to ensure all locking pins are in place
✔️ Replace damaged or missing pins immediately
✔️ Train staff on the importance of securing beams properly

8. Corrosion and Rust Formation

Rust weakens metal over time, reducing the strength of racking components. Warehouses with high humidity levels, leaks, or poor ventilation are particularly at risk.

Prevention Tips:

✔️ Maintain a dry, well-ventilated environment
✔️ Use corrosion-resistant coatings for racking in humid areas
✔️ Conduct frequent inspections and address rust issues early

9. Out-of-Verticality (Leaning Racks)

Racking should remain perfectly vertical. If uprights start to lean, it indicates floor instability, overloading, or frame damage. Any tilt greater than 1/200 under load is a serious safety concern.

Prevention Tips:

✔️ Regularly check racking for misalignment or displacement
✔️ If tilting exceeds safe limits, consult a SEMA Approved Racking Inspector
✔️ Avoid placing excessive weight on one side of the rack

10. Warehouse Floor Damage

Uneven or damaged warehouse floors can cause racking misalignment, instability, and increased impact damage from forklifts.

Prevention Tips:

✔️ Inspect warehouse floors for cracks, uneven surfaces, or shifting
✔️ Repair damaged flooring to prevent racking displacement
✔️ Ensure racking is installed on a level, stable surface

How SEMA Guidelines and SARIs Improve Warehouse Safety

To maintain safe and compliant racking systems, UK warehouses must follow SEMA’s best practices and conduct regular inspections. Partnering with a SEMA Approved Racking Inspector (SARI) ensures that your racking:

✅ Meets UK safety regulations (HSE, PUWER 1998, EN 15635)
✅ Is thoroughly inspected for hidden damage and potential risks
✅ Includes detailed reports with actionable safety recommendations
✅ Remains structurally sound, protecting employees and inventory

Protect Your Warehouse – Book a Racking Inspection Today!

Ignoring racking damage can lead to severe safety hazards, costly disruptions, and legal penalties. By addressing these top 10 damage risks and scheduling regular inspections, businesses can prevent accidents and ensure compliance.

📞 Call A-Z Rack Inspections today at 07947 886161
📧 Email us at sales@a-zrackinspections.co.uk

Let our SEMA Approved Racking Inspectors help you keep your warehouse safe, efficient, and fully compliant!

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