What Happens During a Racking Inspection? A Step-by-Step Guide

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What Happens During a Racking Inspection? A Step-by-Step Guide

When it comes to warehouse safety, racking inspections are one of the most effective ways to protect your people, stock, and storage infrastructure. But many warehouse managers still wonder: what actually happens during a racking inspection?

In this guide, we’ll walk you through the step-by-step process of a racking inspection, explain what inspectors look for, and show why regular inspections are critical for staying compliant with HSE regulations (HSG76) and PUWER.

Why Racking Inspections Matter

Your pallet racking system is a key part of your warehouse operation. If it’s damaged or incorrectly loaded, the risks are serious:

• Collapses leading to workplace accidents and injuries

• Stock damage and costly losses

• HSE enforcement action for non-compliance

• Invalidated insurance claims

The Health and Safety Executive (HSE) makes it clear in HSG76: Warehousing and Storage – A Guide to Health and Safety that racking must be inspected regularly. In fact, HSE recommends a “technically competent” inspection at least once every 12 months—carried out by a SEMA Approved Racking Inspector (SARI).

Step 1: Pre-Inspection Preparation

Before the inspection begins, our SEMA inspector will review:

• Warehouse layout plans – understanding your racking configuration.

• Previous inspection reports – checking if issues have been resolved.

• Traffic routes and forklift usage – identifying high-risk impact zones.

• Load notices and weight limits – ensuring these are visible and correct.

This preparation allows the inspector to focus on the areas most likely to present risks.

Step 2: Visual Examination of Racking

The inspection starts with a detailed visual check of your racking system. Inspectors look for:

• Damaged uprights or frames – dents, bends, or splits caused by forklift impacts.

• Twisted or deflected beams – which can compromise load-bearing capacity.

• Missing safety locks or beam connectors – reducing system stability.

• Corrosion or rust – weakening structural integrity.

• Floor fixings and base plates – checking anchoring is secure.

• Load signs – verifying they are present, visible, and accurate.

Every issue is assessed and recorded in line with the SEMA traffic light risk system.

Step 3: Applying the Traffic Light Risk System

One of the most important parts of the inspection is the SEMA Traffic Light System, which categorises issues by severity:

• Green Risk – minor issues; safe to use but monitor and repair during routine maintenance.

• Amber Risk – damage requiring remedial action; racking can still be used but repairs must be scheduled.

• Red Risk – serious damage or immediate danger; racking must be offloaded and isolated until repaired.

This system helps managers prioritise actions and ensures nothing is overlooked.

Step 4: Recording and Reporting

Once the inspection is complete, the inspector provides a comprehensive written report. This includes:

• A full list of all defects found, with photographs.

• A breakdown of risks by the traffic light categories.

• Recommendations for repairs, replacements, or safety improvements.

• A log to help monitor future inspections and ongoing issues.

This report not only supports HSE compliance but also serves as vital evidence for insurance providers.

Step 5: Repair and Follow-Up

The inspection doesn’t end with the report—it’s about taking action. Depending on the findings, you may need to:

• Isolate unsafe racking immediately (Red Risks).

• Schedule repairs or component replacements.

• Retrain staff on safe use and internal inspections.

• Update racking protection measures (e.g., barriers, upright guards, or bollards).

By acting quickly, you prevent minor issues from escalating into major safety hazards.

Internal Inspections vs. Annual Expert Inspections

While annual inspections by a SEMA Approved Inspector are mandatory, you also need regular in-house checks:

• Daily visual checks by trained staff – spotting obvious damage.

• Weekly or monthly internal audits – recording issues for repair.

• Annual inspections – carried out by a SEMA Approved Racking Inspector.

This combined approach ensures a layered safety strategy that keeps your warehouse compliant and your workforce protected.

The Benefits of Regular Racking Inspections

• ✅ Maintain compliance with HSG76 and PUWER regulations

• ✅ Reduce the risk of accidents and racking collapses

• ✅ Extend the lifespan of your storage system

• ✅ Minimise costly downtime and stock loss

• ✅ Support insurance claims with documented evidence

Book Your Racking Inspection Today

At A-Z Rack Inspections Ltd, we provide expert inspections carried out by SEMA Approved Inspectors. Our detailed reports, practical advice, and compliance-focused service give you peace of mind that your warehouse is safe and legally compliant.

📞 Call us on 07947 886161 or 07917 664940
📧 Email: sales@a-zrackinspections.co.uk

Stay safe. Stay compliant. Protect your business with professional racking inspections.

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