Optimising Warehouse Storage for RITS Logistics

Case Study: Transforming Storage Capacity for Rail Installation & Technical Services Ltd

Client: Rail Installation & Technical Services Ltd
Location: Caldicot, South West
Sector: Logistics & Warehousing
Product: Link 51 Racking – Standard Adjustable Pallet Racking (APR)


The Challenge

When Rail Installation & Technical Services Ltd (RITS) looked to support the rapid expansion of their sister company, RITS Logistics, they were faced with a significant challenge: converting a new South West facility into a highly efficient, scalable, and future-ready storage hub.

The logistics sector is under increasing pressure to respond quickly to customer demands, with the rise of e-commerce and fast-moving supply chains. For RITS, this meant their new facility needed to do more than simply provide pallet storage. It had to deliver the flexibility to handle fluctuating stock volumes, offer compatibility with both UK and Euro pallets, and provide the resilience to adapt as their client base and material handling requirements grew.

With a growing fleet of material handling equipment and a reputation built on customer-first service, RITS knew that wasted floor space, restricted access, or limited load capacity were not options. They needed a racking solution that could provide maximum yield per square foot while allowing them to scale operations smoothly in the years ahead.

Rail Installation & Technical Services Ltd New Install


The Solution

Rack Group partnered with RITS to design, supply, and install a tailored racking system that would meet their ambitious requirements. As one of the UK’s leading racking specialists, Rack Group brings decades of expertise in storage optimisation, safety, and compliance. Drawing on this knowledge, Rack Group selected Link 51 standard adjustable pallet racking (APR) as the ideal solution.

This trusted system has long been a mainstay in the warehousing and logistics sector, providing strength, versatility, and cost-effectiveness in equal measure. The installation was carefully planned and configured to maximise pallet capacity without compromising accessibility or safety.

Key features of the project included:

  • Racking height: 6 metres, making full use of the building’s vertical space.
  • Bay depth: 1100mm, with back to back runs allowing storage of pallets for maximum efficiency.
  • Beam width: 2700mm, optimised for safe pallet handling and maximum load per level.
  • Pallet compatibility: Designed to store both UK (1200 x 1000mm) and Euro (1200 x 800mm) pallets.
  • Load capacity: Each level capable of storing loads up to 2 tonnes, ensuring durability for diverse goods.
  • Integrated Rack Armour® racking upright guards: Each Racking Upright is equiped with Rack Armour for improved safety and reduced maintenance costs

The design ensured RITS could achieve maximum throughput without bottlenecks. Flexibility was central to the installation, allowing for easy reconfiguration as storage demands change. Rack Group’s in-house team worked closely with RITS, from concept design through to final handover, ensuring the racking met current needs and anticipated future growth.

Rail Installation & Technical Services Ltd New Install

Enhanced Protection with Rack Armour® Upright Protection

In addition to the racking installation, Rack Group also incorporated Rack Armour® racking upright guards to provide long-term protection for the uprights. Manufactured from highly resilient polymer, Rack Armour offers exceptional impact resistance, reducing the likelihood of costly damage from forklift and pallet truck collisions. By extending the lifespan of the racking and lowering ongoing maintenance costs, this added layer of protection ensures that RITS’s new installation remains safe, durable, and cost-effective well into the future.


The Result

The completed installation has transformed RITS Logistics’ South West facility into a highly efficient, scalable warehouse operation. The optimised design means every square foot of floor space is now working harder, accommodating a greater number of pallet positions while maintaining safe and accessible aisles for the company’s growing reach truck fleet.

By catering to both UK and Euro pallet sizes, the system enhances RITS’s flexibility to serve a wider customer base, ranging from businesses with small, short-term storage needs to those requiring large-scale, long-term warehousing. This aligns perfectly with their client promise: whether it is one pallet for one day or 200 pallets for two years, RITS can provide a dependable solution.

The investment in new racking, coupled with the addition of a reach truck, has significantly improved operational efficiency. It ensures faster pallet retrieval, reduced handling times, and improved overall flow within the warehouse. The installation has also reinforced RITS’s ability to scale operations quickly in response to client demand, strengthening their position within the competitive logistics and warehousing sector.

Rail Installation & Technical Services Ltd New Install V3


Why Rack Group?

Rack Group was chosen not just for its ability to deliver high-quality installations but also for its holistic approach to storage solutions. As The Racking Experts, Rack Group provides a complete service that extends beyond installation. This includes ongoing safety inspections, repairs, maintenance, and training, ensuring clients like RITS remain compliant with industry standards such as SEMA and EN15635.

For RITS, partnering with Rack Group meant having a trusted advisor who could deliver a tailored solution today while offering the support and expertise needed to keep the racking safe and effective for years to come. This combination of technical knowledge and customer care was a key factor in the success of the project.


Testimonial

RITS shared their satisfaction with the project in a LinkedIn post, stating:

“We are extremely pleased with our new racking – thanks to Rack Group for designing and installing, ensuring the best yield per sq ft.”
– Rail Installation & Technical Services Ltd


Looking Ahead

The successful completion of this project highlights the importance of strategic investment in storage infrastructure. By choosing a system that maximises space, enhances flexibility, and ensures long-term adaptability, RITS have future-proofed their South West facility against the challenges of an evolving logistics market.

For Rack Group, this project is a testament to the value of collaborative planning and tailored solutions. It demonstrates how the right racking system, installed with precision and supported by industry experts, can transform a warehouse into a high-performance, customer-centric operation.

As RITS continues to grow alongside RITS Logistics, they now have the confidence that their storage capacity can grow with them, ensuring they remain at the forefront of the logistics and warehousing sector in the South West and beyond.

The Full Racking Lifecycle with Rack Group

At Rack Group, part of the IWS Group, we support businesses throughout the entire racking lifecycle. From initial design and installation to inspections, repairs, and ongoing maintenance, we ensure your storage systems remain safe, efficient, and compliant. Beyond racking, we also provide a comprehensive range of workplace safety solutions, including impact protection, barriers, bollards, and car park protection systems.

Through the wider group offering, customers can also access a complete suite of complementary products to support day-to-day operations. These include warehouse identification and visual management solutions such as labelling, signage, and shadow boards, alongside versatile storage equipment like shelving systems and plastic storage containers. Together, these solutions help improve efficiency, organisation, and safety across any facility.

Whatever your workplace requires, Rack Group and the IWS Group deliver the expertise and solutions to keep your operations running smoothly and your people safe.

Top 10 Racking Regulations for Warehouse Safety

Top 10 Racking Regulations Every Warehouse Owner and Manager Should Know

In any warehouse environment, safety is not optional. It is a legal obligation that protects employees, contractors and, ultimately, your business. A failure to meet safety obligations will lead to near misses, serious incidents or even fatalities. It may also expose your business to expensive legal action and regulatory scrutiny.

Rack Group Lifecycle Email Image

From pallet racking installation to daily warehouse operations, owners and site managers must ensure their facilities operate efficiently while remaining fully compliant with current UK legislation and best practices. Without proper compliance, businesses also risk serious injuries, financial penalties and long-term reputational harm.

Rack Group Acquired By IWS Group

At Rack Group, we help businesses create safe, efficient and legally compliant warehouse environments. As part of IWS Group, we deliver a fully integrated network of safety solutions, inspection programmes and training services. These are designed to reinforce best practice in line with HSE guidance, PUWER regulations and SEMA standards.

In this guide, we’ve outlined the 10 most important regulations warehouse operators should understand and implement. These rules are essential for ensuring racking safety, workplace compliance and long-term operational success.

Why Racking Safety Matters

Racking systems form the backbone of warehouse operations. They support the safe storage of goods, optimise space and enable efficient workflows. However, when racking is poorly maintained or incorrectly installed, it can pose serious safety risks. These risks include pallet collapses, falling stock, forklift collisions and even life-threatening injuries.

That is why racking safety is not just a legal requirement, it is a critical component of your warehouse’s operational integrity and overall workplace wellbeing. In many cases, incidents caused by racking failure can be avoided through regular inspection and proactive maintenance.

At Rack Group, we do more than install pallet racking. We provide:

Our services help warehouse teams identify damage early, reduce risk and remain fully compliant with UK regulations. Additionally, we collaborate with end users, contractors and site managers to ensure racking systems are correctly designed, safely installed and fit for purpose from the outset.

Rack Armour

10 Key Regulations Warehouse Operators Must Know for Safe Racking Systems

Racking safety is more than just best practice. It is a legal requirement that protects your workforce and safeguards your operations. Every warehouse owner and manager must understand the key regulations that govern safe storage systems and workplace practices in the UK.

These rules come from both statutory legislation, such as the Health and Safety at Work Act, and industry-specific standards, including guidance from SEMA and the HSE. Following these frameworks helps prevent accidents, reduce operational risks, and avoid costly damage or downtime.

In this section, we highlight the 10 most important regulations and safety standards that directly affect racking systems. By understanding and applying each one, you can ensure your warehouse remains compliant, efficient, and safe for everyone on site.

1. Health and Safety at Work Act 1974

The Health and Safety at Work Act 1974 is the cornerstone of UK workplace safety legislation. It places a legal duty on employers to protect the health, safety and welfare of their employees, as well as anyone else who could be affected by their operations.

This Act forms the basis for all other health and safety regulations in the UK and applies directly to warehouse environments.

In the context of racking, this legislation requires warehouse operators to:

  • Ensure all racking systems are structurally sound, properly maintained and never overloaded
  • Provide adequate training for staff working around or with racking and materials handling equipment
  • Implement safe working practices and take proactive measures to prevent accidents and injuries

By complying with this legislation, warehouse managers demonstrate a commitment to legal and moral responsibility. It also helps to create a safety-first culture that protects both people and property.

PRRS Racking Training
Double Bumper Pedestrian Barrier

2. Workplace (Health, Safety and Welfare) Regulations 1992

The Workplace (Health, Safety and Welfare) Regulations 1992 set out the minimum standards required to create a safe and healthy working environment. These apply to all workplaces, including warehouses, and cover a wide range of safety considerations related to infrastructure and day-to-day operations.

In a warehouse setting, the regulations require:

  • Clearly marked and unobstructed access routes to enable safe movement of personnel and vehicles
  • Safe and even floor conditions, free from hazards such as spills or damaged surfaces
  • Adequate lighting to ensure visibility across all racking and storage areas
  • Sufficient space for the safe installation of racking and the safe operation of material handling equipment

In addition, physical racking protection, such as bollards, barriers and impact guards, plays a key role in helping businesses meet these safety standards. These measures reduce the risk of damage to structural racking and improve overall site safety.

By complying with these regulations, warehouse operators help reduce the risk of accidents and demonstrate a proactive commitment to worker welfare.

3. Manual Handling Operations Regulations 1992

The Manual Handling Operations Regulations 1992 aim to reduce the risk of injury caused by lifting, carrying, pushing or pulling heavy loads. These regulations are particularly relevant in warehouses, where manual handling is a routine part of operations.

For racking environments, employers must:

  • Avoid manual handling tasks wherever reasonably practicable, especially when mechanical alternatives are available
  • Conduct detailed risk assessments to identify potential hazards linked to manual handling activities
  • Design racking and shelving systems at ergonomically appropriate heights to reduce strain on workers

In addition, businesses should use mechanical handling aids such as pallet trucks, trolleys or hoists to move heavy goods safely. Operatives must also receive comprehensive training in correct lifting techniques and posture to help prevent musculoskeletal injuries.

By following this legislation, warehouse managers can significantly reduce the risk of injury and improve overall efficiency across manual handling tasks.

Pedestrian Bumper Barriers Single
Close-up of a metal corner guard installed on push-back racking, providing impact protection where standard Rack Armour does not fit.

4. Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)

The Lifting Operations and Lifting Equipment Regulations 1998, commonly known as LOLER, regulate the safe use of lifting equipment in the workplace. These rules apply to a wide range of machinery used in warehouses, including forklifts, pallet stackers, cranes and hoists.

Employers are legally required to ensure that:

  • Lifting equipment is suitable, safe and fit for its intended purpose
  • All equipment is regularly maintained, thoroughly examined and clearly labelled with its Safe Working Load (SWL)
  • Lifting operations are properly planned, supervised and carried out by trained, competent personnel

These steps are especially important during the loading and unloading of pallet racking systems, where improper lifting can lead to serious damage or injury.

By complying with LOLER, warehouse operators help protect their workforce and ensure that all lifting activities are carried out safely and efficiently.

5. Provision and Use of Work Equipment Regulations 1998 (PUWER)

The Provision and Use of Work Equipment Regulations 1998 (PUWER) apply to all equipment used in the workplace, including warehouse racking systems. This legislation ensures that work equipment is safe to use, properly maintained and suitable for its intended purpose.

Under PUWER, employers must ensure that:

  • Racking systems are suitable for their specific use and are installed according to manufacturer guidelines or recognised industry standards
  • Regular inspections and maintenance are carried out to identify and address wear, damage or deterioration
  • Only trained and authorised personnel are allowed to use or work around the equipment, including forklifts and other handling tools interacting with racking

It is essential to treat racking as work equipment, not just as passive storage. This mindset supports compliance with PUWER and helps reduce the risk of structural failure or workplace injury.

By following PUWER, warehouse operators protect their staff and demonstrate a clear commitment to workplace safety.

Rack Armour
Cantilever Racking

6. Management of Health and Safety at Work Regulations 1999

The Management of Health and Safety at Work Regulations 1999 require employers to take a proactive and systematic approach to managing risks across the workplace. These regulations build upon the core duties established in the Health and Safety at Work Act and focus on risk prevention, planning and supervision.

In warehouse environments, operators must:

  • Carry out regular risk assessments, including specific assessments for racking layout, usage and surrounding activity
  • Implement appropriate preventative measures, such as barriers, signage and traffic management systems
  • Ensure all employees receive proper training and are supervised during safety-critical tasks

One of the most important elements of compliance is having a formal racking damage reporting system in place. This ensures that any issues are identified early, recorded accurately and addressed quickly before they lead to more serious hazards.

By managing risks proactively, warehouse operators reduce incidents, improve safety and support a compliant working environment.

7. Work at Height Regulations 2005

The Work at Height Regulations 2005 apply to any task carried out above ground level, including common warehouse activities such as installing racking beams, accessing high storage areas or using ladders and order pickers.

Warehouse employers must:

  • Avoid working at height wherever possible, by redesigning tasks or using ground-level alternatives
  • Provide the correct fall protection equipment, such as harnesses, guardrails or safety cages
  • Ensure all workers receive appropriate training and supervision when carrying out tasks at height

Even short-duration tasks, such as retrieving stock from upper levels, must be properly assessed, planned and executed using safe access methods.

By following these regulations, employers reduce the risk of serious injury and help create a safer working environment for everyone involved in warehouse operations.

Capita 1
Brandsafe Rack End Barriers

8. Construction (Design and Management) Regulations 2015 (CDM)

The Construction (Design and Management) Regulations 2015 (CDM) apply to a wide range of construction-related activities. This includes large-scale warehouse fit-outs, complex racking installations and, in some cases, even minor alterations or refurbishments.

Under CDM, warehouse operators and project stakeholders must:

  • Appoint duty holders, such as a principal designer and principal contractor, to manage health and safety throughout the project
  • Develop a construction phase plan that identifies risks and outlines control measures
  • Consider health and safety at every stage, from the design and installation of racking systems to their ongoing use and maintenance

Even relatively straightforward racking installations may fall under CDM requirements, particularly when part of a new-build project or a significant refurbishment.

By complying with CDM, businesses ensure that safety is embedded from the outset and maintained throughout the project lifecycle.

9. HSG76 – Warehousing and Storage: A Guide to Health and Safety (HSE, 2007)

HSG76 is a detailed guidance document published by the Health and Safety Executive (HSE). Although not legislation, it is widely accepted as the industry benchmark for warehouse safety best practice. Insurers, auditors and health and safety inspectors regularly reference it when assessing compliance.

The guide outlines best practices for maintaining a safe and efficient storage environment. Key topics include:

  • Correct racking layout, including aisle widths and pallet positioning
  • Safe stacking techniques, pallet quality and load distribution
  • Traffic management, particularly the safe interaction between forklifts and pedestrians
  • Racking inspections, including damage classification (red, amber and green) and clear repair protocols

One of the most important recommendations in HSG76 is the appointment of a PRRS (Person Responsible for Racking Safety).

This designated individual should receive appropriate training and have the authority to:

  • Oversee the condition and safety of racking systems
  • Manage and document routine in-house inspections
  • Ensure damaged racking is reported and addressed promptly
  • Liaise with qualified professionals, such as SEMA Approved Racking Inspectors (SARIs), for annual expert inspections

Appointing a PRRS ensures clear accountability and supports proactive racking management. Many warehouse incidents occur because no one has been formally assigned to monitor racking safety. The PRRS role fills this gap and helps uphold a robust safety culture.

While HSG76 is not a legal requirement, failure to follow its guidance can be used as evidence of negligence in the event of an incident.

Racking Training
Racking Install

10. BS EN 15635:2008 – Steel Static Storage Systems: Application and Maintenance of Storage Equipment

BS EN 15635:2008 is the key British and European standard governing the safe use, inspection and maintenance of steel static storage systems, including pallet racking. It provides precise guidance to help warehouse operators manage racking safety throughout its lifecycle.

This standard outlines the responsibilities of both racking suppliers and system users. Key areas of focus include:

  • User and supplier responsibilities, including correct installation and safe usage procedures
  • Inspection routines, such as regular internal checks (daily or weekly) and expert inspections conducted annually by a qualified specialist
  • Damage classification, using a colour-coded system: Green (monitor), Amber (schedule repair), and Red (immediately offload and isolate)
  • Record-keeping protocols, including how to document inspections, assess damage and take corrective action

BS EN 15635 is widely recognised across the industry and forms the foundation of most professional racking inspection frameworks. Adhering to this standard not only supports legal compliance but also shows clear evidence of due diligence and proactive safety management.

By following BS EN 15635, warehouse operators can maintain a consistent, structured approach to racking safety that minimises risk and extends the operational life of their storage systems.

Additional Standards and Regulations to Be Aware Of

SEMA Codes of Practice

The Storage Equipment Manufacturers Association (SEMA) sets the standard for best practice in the design, installation, inspection and maintenance of racking systems across the UK.

SEMA's codes of practice are widely recognised and followed by manufacturers, installers and health and safety professionals. Key components include:

  • The SEMA Code of Practice for the Use of Static Pallet Racking, which provides essential guidance on safe usage
  • Clear instructions on beam placement, load signage, tolerances and installation procedures
  • The SEMA Approved Racking Inspector (SARI) scheme, which certifies professionals to carry out expert racking inspections

Following SEMA guidance demonstrates a strong commitment to warehouse safety and regulatory compliance. It is frequently referenced by HSE inspectors and insurers as the industry benchmark for safe racking systems.

By adopting SEMA standards, warehouse operators can reduce risk, improve system longevity and ensure that all racking installations meet the highest safety expectations.

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Racking Collapse Shrewsbury   Image Source Aaron Chown SWNS Copy

RIDDOR – Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013

The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013 (RIDDOR) requires employers to report specific types of workplace incidents to the Health and Safety Executive (HSE). This legislation applies directly to warehouse environments where racking systems are in use.

Under RIDDOR, you must report any serious incident involving racking, including:

  • Structural failures, such as a partial or full collapse of racking systems
  • Dangerous occurrences, including falling loads or significant racking damage
  • Injuries resulting in more than seven consecutive days off work
  • Near-misses that had the potential to cause serious harm or death

Timely and accurate reporting is not only a legal requirement, it is also essential for identifying root causes and preventing future incidents.

By complying with RIDDOR, warehouse operators demonstrate accountability and strengthen their overall approach to health and safety management.

Related Systems That Reinforce Safety

Compliance is not achieved through policy alone. It requires the right physical systems to support safe working practices across your warehouse. That is where the wider IWS Group product range becomes essential.

We offer a comprehensive selection of safety solutions that work in harmony with your racking systems:

  • Rack Armour® Upright Protectors: Absorb impacts and reduce racking damage by up to 80 percent, helping to protect your investment and extend the lifespan of your storage systems
  • Pedestrian Safety Barriers (PAS 13 tested): Physically and visually separate material handling equipment (MHE) from foot traffic to reduce collision risks
  • Floor Rail Bumpers: Prevent forklifts from entering pallet lanes or pedestrian zones, improving aisle safety and traffic control
  • Safety Signage: Clearly mark risk areas and racking load capacities using magnetic labels, colour-coded markers or floor-mounted visuals
  • Shelving Systems: Anco’s robust longspan shelving provides safe and accessible storage for non-palletised goods
  • Bollards and Column Guards: Shield structural posts and high-risk zones from impact damage with flexible, highly visible protection

Together, these systems create a fully integrated, safety-first warehouse environment. This not only strengthens compliance but also improves operational efficiency, reduces risk and gives your team greater confidence in their working conditions.

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Inspections, Training and Aftercare from Rack Group

Understanding racking regulations is only the first step. The real challenge lies in ongoing compliance. That’s where Rack Group comes in - delivering expert inspections, tailored training, and proactive aftercare to keep your warehouse operations safe, compliant and efficient.

Our SEMA Approved Racking Inspectors (SARIs) carry out annual inspections with detailed reports that highlight actionable improvements. We also offer preventative maintenance contracts to help you spot and resolve issues before they escalate. For internal teams, our PUWER and SEMA-aligned training equips operatives to take on the role of PRRS (Person Responsible for Racking Safety), ensuring accountability is embedded into your operation.

To support day-to-day safety, we supply damage detection tools and best practice resources that align with HSE guidance and help maintain high standards across your site.

By partnering with Rack Group, you ensure that your racking systems are expertly maintained, risk is minimised, and system longevity is maximised — all while meeting regulatory expectations.

Final Thoughts: Build Compliance into Your Warehouse Culture

Safety is not a tick-box exercise. It’s an ongoing responsibility that must be embedded into your warehouse culture. Staying informed, investing in high-performance protection systems and ensuring your staff are trained to spot hazards early are key to reducing risk, protecting people and avoiding disruption.

At Rack Group, part of the IWS Group, we help create safer, smarter and more compliant warehouse environments. From racking inspections and impact protection to warehouse labelling and modular storage, we provide a full suite of solutions that support long-term operational resilience.

Discover More About Rack Group

Built on a foundation of safety, innovation and customer care, Rack Group is your trusted partner for managing the full lifecycle of your racking systems.

Our services include:

Whether you’re upgrading an existing system or planning a new facility, our solutions are designed to minimise risk, support compliance and keep your warehouse running smoothly.

Explore our services and product range to ensure your racking systems meet UK regulatory expectations. Visit our case studies to see how we have helped businesses prevent costly damage and enhance workplace safety. For expert advice or to get started, contact us today and discover how Rack Group can support your warehouse safety needs.

Maximising Warehouse Efficiency

Maximising Warehouse Efficiency: Racking Installation and Strategic Relocation to Optimise Storage Capacity

At Rack Group, we specialise in maximising warehouse efficiency through storage design, racking installation, and optimisation, helping businesses make the most of their available space. Our latest project involved both a new pallet racking installation and a push-back racking relocation, ensuring our customer could store their stock more efficiently, improve warehouse flow, and enhance their overall operational productivity.

With over 40 years of experience in racking solutions, we understand how crucial it is to maximise storage density while maintaining accessibility and compliance. This project is a prime example of how strategic relocation and a well-planned racking installation can increase warehouse efficiency. Below, we share how this project successfully increased our customer’s storage capacity and streamlined their operations.

New Pallet Racking Installation – Expanding Storage Capacity

As businesses grow, so do their storage needs. The customer required an increase in storage capacity within their main warehouse. To achieve this, we installed new pallet racking units along the warehouse walls, making use of available vertical space while keeping aisles clear for efficient stock movement. This racking installation was designed to ensure seamless stock handling and workflow improvements.

Optimised Use of Available Space

By placing the new racking against the far warehouse walls, the design ensured that previously underutilised space could be used for storage while maintaining clear operational areas. This approach increases stock density without compromising workflow efficiency, which is a critical aspect of maximising warehouse efficiency.

Increased Storage Capacity

The additional pallet racking units allowed the customer to increase stock levels within their main warehouse, ensuring they could store and access products more efficiently. This is particularly important for businesses handling large volumes of inventory, as it helps them keep up with demand without requiring additional floor space.

Improved Warehouse Organisation and Compliance

Every new racking installation must be designed with efficiency and safety in mind. To enhance both, the racking was equipped with:

  • Racksack® – Organised waste management to keep aisles and storage areas free from debris, maintaining a safe working environment.
  • Bay Markers – Clear labelling to help warehouse staff quickly locate and retrieve stock, reducing picking times and minimising errors.
  • Weight Load Notices – Ensuring regulatory compliance by displaying maximum load capacities, reducing the risk of overloading and structural damage.
  • Rack Armour® – Protecting racking uprights from forklift and pallet truck impacts, extending the lifespan of the racking.

Results of the Installation: By implementing these well-planned storage solutions, the customer can now hold more stock, improve order fulfilment speeds, and reduce congestion in the warehouse. This project is a testament to how a properly executed racking installation can enhance overall efficiency.

Pallet racking fitted with wooden slats, designed for small part storage, allowing for labelled organisation of fixings and fastenings.
Close-up of a Rack Armour protector installed on a pallet racking upright, designed to prevent impact damage and enhance warehouse safety.
Warehouse utilising newly installed pallet racking for outgoing packages, positioned next to push-back racking to showcase full storage height and efficiency.

Push-Back Racking Relocation – Unlocking Space and Efficiency

While adding new storage is important, reconfiguring existing racking can be just as beneficial when it comes to improving warehouse efficiency. This strategic relocation project played a key role in optimising the customer’s available space.

Our customer needed to relocate their push-back racking system while also reducing the number of bays from eight to four. This move was necessary to accommodate a new process within the warehouse, ensuring smoother operations while maintaining optimal storage capacity.

Strategic Repositioning for Improved Workflow

The racking relocation allowed the customer to free up space for a new process, while keeping essential storage capacity intact. This strategic move created a more streamlined warehouse layout, allowing staff and equipment to move more freely without obstruction maximising warehouse efficiency. The efficiency gained from this racking relocation underscores the value of a well-planned storage system.

Increased Storage Capacity Within the Warehouse

By repositioning the push-back racking, the customer could consolidate stock more effectively, reducing the need for additional expansion while still maintaining easy access to inventory. Research by the Warehouse Education and Research Council (WERC) shows that optimised warehouse storage solutions can improve operational efficiency by up to 25%, proving the impact of a well-planned racking relocation.

Better Use of High-Density Storage

Push-back racking is an excellent solution for businesses looking to store multiple pallets per lane while maintaining efficient stock rotation. By reducing the bays and strategically repositioning the racking, the customer was able to:

  • Maximise high-density storage by reducing aisle space and storing multiple pallets deep in a single lane.
  • Improve inventory rotation with a last-in, first-out (LIFO) system, ensuring a continuous flow of goods.
  • Optimise warehouse footprint by making the best use of available space while keeping stock easily accessible for staff.

Results of the Relocation: This project not only freed up space for the customer's new process, but also ensured their main warehouse could handle more stock, reduce congestion, and improve overall warehouse operations. This successful racking relocation demonstrates the importance of strategic planning in warehouse efficiency.

Close-up of a Rack Armour protector installed above the first beam on push-back racking, designed to safeguard the middle beam from potential impacts.
Close-up of a metal corner guard installed on push-back racking, providing impact protection where standard Rack Armour does not fit.
Close-up view of the completed push-back racking installation, showcasing half the bays and full height for efficient warehouse storage.

Enhancing Warehouse Safety with Floor Rail Bumpers Now 50% Off: Only £38.50 (While Stocks Last)!

Alongside racking installations and relocations, warehouse safety is a top priority. To help businesses protect their racking, machinery, and walkways, we’re currently offering a limited-time discount on our Safety Yellow Floor Rail Bumpers.

Why Choose Floor Rail Bumpers?

  • Impact Absorption – Crafted from durable HDPE, these bumpers help absorb and deflect forklift and pallet truck impacts.
  • Cost-effective Protection – Prevents costly damage to racking and machinery, reducing downtime and maintenance costs.
  • Space-saving Design – The compact size integrates seamlessly into warehouse layouts without obstructing workflow.

Stock is limited, so take advantage of this offer before it’s gone!

Floor rail bumper installed beneath racking and machinery to protect critical uprights and delicate equipment from forklift tines and MHE impacts.
Warehouse safety installation featuring polymer safety barriers with integrated safety gates, ImpactSAFE Bollards protecting the loading bay door and walkway, and a floor rail bumper preventing forklift and MHE intrusion beneath the barriers.
Close-up of a safety yellow floor rail bumper installed beneath machinery and racking to protect uprights and equipment from forklift and MHE damage.
Final Thought – Is Your Warehouse Storage Working for You?

Every warehouse is unique, and achieving optimal efficiency requires storage solutions that align with your specific operational needs. Whether you are expanding, relocating, or reassessing your current systems, ensuring that your racking and storage infrastructure supports both productivity and safety is essential.

At Rack Group, we provide expert guidance and tailored solutions to help you optimise your warehouse, offering:

Beyond storage solutions, we deliver a full suite of warehouse safety services, including SEMA-approved racking inspections, maintenance, repairs, impact protection, and staff training. These services help minimise downtime, extend the lifespan of your racking systems, and enhance overall workplace safety.

If you are looking to expand your storage capacity, improve warehouse efficiency, or enhance safety measures, our team is here to assist. Contact Rack Group today to discuss how we can support your business in creating a safer, more efficient warehouse environment.

Discover More About Rack Group

Rack Group, as part of IWS Group, is driven by a commitment to safety, innovation, and customer satisfaction. Whether you need expert installations and alterations or tailored safety solutions, Rack Group is your trusted partner for optimising warehouse operations.

We offer a comprehensive range of services, including pallet racking inspections, rack inspection services, racking inspection training, and a racking inspection course to ensure your warehouse remains compliant and efficient. Our expertise extends to racking inspections, maintenance and repairs, training, impact protection, and warehouse and racking accessories.

Explore our services and products to ensure your racking systems meet the highest safety standards. View our case studies to see how we’ve helped businesses prevent costly disruptions and enhance operational safety. For the latest insights, check out our blog and contact us today to learn how Rack Group can support your warehouse safety needs.

The Importance of Regular Racking Inspections for Warehouse Safety

The Importance of Regular Racking Inspections

Pallet Racking Inspections

Warehouses play a vital role in many industries by supporting storage, logistics, and distribution. However, they can also present significant safety risks, particularly with racking systems used for bulky materials storage. While racking systems are engineered to hold heavy loads and optimise storage efficiency, they are susceptible to damage over time. Everyday wear and tear, accidental impacts from equipment, and an inadequate maintenance schedule can compromise the integrity of any racking system. If these issues are left unchecked, they can lead to severe accidents, including racking collapses that can endanger workers and inventory. This underlines the importance of regular racking inspections, which are not only a legal requirement but a critical step in maintaining a safe warehouse environment.

The Standards and Regulations

The European Standard EN 15635 Steel Static Storage Systems - Application and Maintenance of Storage Equipment outlines safety regulations for pallet racking inspections and repairs. Specifically, Section 9.4.2.3 (Expert Inspections) mandates that inspections must be conducted by technically competent individuals every 12 months. These inspections should result in a detailed report with observations and recommendations for corrective actions, to be presented to the Person Responsible for Storage Equipment Safety (PRSES).

Safety Culture

Routine inspections go beyond meeting compliance standards; they play a key role in ensuring workplace safety and operational efficiency. Regular inspections allow for the early detection of minor issues before they escalate into costly or dangerous problems. By committing to these proactive measures, warehouses can maintain smooth operations, meet safety standards, and keep up with the fast pace of industrial work.

Additionally, regular inspections foster a culture of safety by systematically examining all racking components and addressing potential problems before they become critical. This approach not only enhances workplace safety but also promotes a sense of accountability among warehouse staff, increasing awareness of the crucial role racking systems play in daily operations. By prioritising proactive maintenance, warehouses can support continuous improvement and minimise disruptions caused by unexpected failures, enabling facilities to operate at peak efficiency. Book your Racking Inspection Today.

Rack Group: Your Partner for Racking Inspections

At Rack Group, we provide thorough racking inspection services to keep your warehouse safe, compliant, and efficient. The Rack Group name may have been born in 2002, but our work history, and love of all things racking, goes back to the 1980s. With over 40 years of experience and hundreds of satisfied clients, working with Rack Group ensures that your warehouse operations are in expert hands.

 

 

Our approach is based on years of industry experience and dedication to the highest standards, making us a trusted partner for businesses looking to strengthen their warehouse operations. We understand the complexities involved in running a warehouse, and our mission is to ensure that the racking systems that form the backbone of your storage processes are well-maintained and safe for day-to-day use.

Why Racking Inspections are Essential

1. Compliance with Industry Standards

Warehouses must adhere to strict safety regulations, such as those outlined in the European standard EN 15635 - Steel Static Storage Systems - Application and Maintenance of Storage Equipment. Section 9.4.2.3, Expert Inspections, specifies that inspections should be conducted by technically competent individuals every 12 months. A report containing observations and recommendations for any necessary actions must be presented to the Person Responsible for Storage Equipment Safety (PRSES).

Our racking inspectors are accredited by two distinguished bodies: the Storage Equipment Manufacturers Association (SEMA) and the Provision and Use of Work Equipment Regulations (PUWER). These standards are designed to protect both workers and inventory by mitigating risks associated with handling and storage. Regular inspections ensure these standards are consistently met, reducing the risk of penalties and maintaining a safe work environment. Compliance is not just about avoiding fines; it demonstrates a commitment to safety and operational excellence.

 

 

Regular inspections also provide documentation that can be crucial during audits or reviews by regulatory bodies. This documentation can serve as evidence of your facility’s adherence to established safety standards, giving you peace of mind and providing assurance to stakeholders, partners, and employees. When you can demonstrate that your warehouse meets all safety requirements, you gain a competitive edge, showing that your operations are reliable and safe.

2. Preventing Accidents

Damaged racking systems are a major safety hazard. If they fail, they can cause injuries to workers and damage to inventory. The costs of these incidents go beyond just repairs, often including compensation claims, regulatory fines, and the long-term impact of disrupted operations. Inspections help identify issues early, allowing for repairs that can prevent accidents. By spotting structural weaknesses — whether due to overloading, wear, or accidental impacts — inspections act as a key risk management tool, ensuring problems are addressed before accidents happen.

Beyond preventing injuries and damage, inspections also help to foster a safer working environment, which can lead to better morale and productivity among staff. Employees who feel safe at work are more likely to stay focused and perform well, and they are less likely to miss work due to injury. In essence, investing in regular inspections translates to fewer disruptions, more efficient workflows, and an overall positive atmosphere in the workplace.

3. Saving Money

Fixing minor racking damage early is much cheaper than dealing with a major failure. Waiting until something breaks is inefficient and can lead to unplanned disruptions, which are costly to productivity. Regular inspections allow for preventive maintenance, reducing downtime and saving money. By identifying problems before they become serious, businesses can avoid the high costs that come with unexpected system failures. This proactive approach to maintenance keeps repairs targeted and manageable, preventing more expensive issues from developing.

Cost savings also extend to avoiding potential regulatory fines and legal costs. Non-compliance can be extremely costly, not only in terms of fines but also in the time and resources required to correct issues after a violation has been identified. By addressing issues early and continuously maintaining the integrity of the racking systems, companies can avoid these unexpected financial hits and allocate their resources to growth and development instead.

4. Protecting Your Investment

Racking systems are a significant investment for any warehouse. Routine inspections help extend the life of these systems by identifying wear and tear early, ensuring that you get the best return on your investment. Keeping racking systems in good shape isn't just about safety — it’s also about protecting the money you have invested. By making racking systems last longer, businesses can delay the need for costly replacements and maintain effective storage for longer periods.

Furthermore, well-maintained racking helps ensure that inventory remains secure and undamaged, contributing to improved overall efficiency and less waste. Damaged pallet racking can cause accidents that lead to lost or spoiled products, which can hurt profitability. Protecting the integrity of your racking systems ultimately helps to protect your bottom line.

The Racking Inspection Process

1. Visual Assessment

Our inspectors conduct a thorough check of the racking system for any visible signs of damage, such as bent uprights, missing bolts, or overloading. Visual inspections are the first step in identifying any obvious issues that could compromise safety. The inspection covers all parts of the racking system to make sure everything meets safety standards. Visual assessments are critical because even small signs of damage, like minor bends or scratches, can indicate larger underlying issues.

Our inspectors are trained to recognise these seemingly minor problems before they become a bigger hazard. On a rare occasion moving Rack Armour or stock might be necessary to see any damage hidden or obstructed form view. However, installing Rack Armour can reduce forklift tine impacts on pallet racking by up to 80% when compared to other racking protection. We ensure that every element, from beams to bolts, is scrutinised so that nothing is overlooked, and safety is prioritised.

2. Load Verification

3. Structural Integrity Evaluation

4. Detailed Reporting

It's important to make sure that racking systems are not overloaded. Overloading can cause serious failures that put both the racking and the stored items at risk. Our inspections verify that the loads comply with manufacturer specifications, ensuring that the racking systems are being used safely and effectively. We also look at how the warehouse staff handle the loading process. Improper stacking or distribution of weight can lead to stress points that increase the risk of collapse. By verifying load limits and providing recommendations on best practices for loading, we help our clients maintain not only compliance but also safety for everyone involved. Rack Group can provide compliant and SEMA-approved Weight Load Notices.

We assess the overall stability of the racking system, looking for potential weaknesses or risks. This evaluation goes beyond just looking for visible damage; it involves a detailed examination of how well the racks are holding up under pressure, including checking joints and alignment. Identifying these hidden risks is crucial to preventing unexpected failures. During structural evaluations, inspectors use tools to assess stress levels and classify actions using SEMA’s Red, Amber, and Green system. This step is vital in determining whether the racking system is still performing as intended, or if it needs maintenance or reinforcement to keep operating safely and efficiently.

Rack Group provides a full report that outlines any issues found, highlighting the causes of racking damage, recommended repairs, and timelines for fixing them. These reports aren’t just records of what’s wrong — they’re tools that help managers make decisions. Our reports give clear guidance on what needs to be fixed and when, helping facilities plan their maintenance work efficiently. Our reports also serve as a roadmap for future inspections and improvements. By keeping a detailed history of the condition of your racking systems, we can help identify patterns in wear and damage, allowing for smarter planning and budgeting for maintenance. This proactive approach helps avoid surprises and ensures that warehouse operations continue without disruption.

The Consequences of Neglecting Racking Inspections

Neglecting routine pallet racking inspections can have serious consequences, such as:

Operational Disruptions:

Higher Accident Risk:

Fines and Legal Issues:

When racking fails unexpectedly, it can cause significant disruptions, delaying order fulfilment and affecting the company’s reputation. Unplanned downtime can also lead to lost business opportunities and a drop in customer trust. Additionally, these disruptions often have a ripple effect across the entire supply chain. When one warehouse cannot fulfil orders due to an equipment failure, it affects suppliers, delivery schedules, and customers. This kind of disruption not only impacts financial performance but can also hurt relationships with clients and suppliers, potentially leading to a long-term loss of business. It is always best to know the main reasons behind racking collapses and how to avoid them.

Racking collapses can result in severe injuries to workers, significant inventory losses, and reputational damage due to legal and financial repercussions. According to official Health and Safety statistics for 2022-2023, workplace incidents related to safety negligence continue to impose substantial costs on businesses across the UK.

Don’t become part of these statistics — ensure your warehouse is compliant and safe by booking a racking inspection today.

Not meeting safety standards can result in fines or other legal consequences. Repeated safety violations can attract more scrutiny from authorities and lead to further penalties. Always refer to governing bodies, legislation, and the best health and safety practices for guidance. The Health and Safety Executive (HSE) is the UK’s regulator for workplace health and safety. It helps to prevent work-related deaths, injuries and ill health.

Rack Group Case Studies: Ensuring Warehouse Safety and Efficiency

Rack Group's inspections have consistently delivered significant value to our clients by providing proactive solutions to maintain warehouse safety and operational efficiency. Below, we've highlighted some case studies that demonstrate our expertise and commitment to quality service.

1. Preventing Structural Failures and Addressing Recurring Issues for Long-term Savings

In a high-traffic warehouse, our inspection team identified significant structural damage that posed a major risk of collapse. Without our timely intervention, this could have led to disastrous consequences, including severe injury, operational disruptions, and high costs. By performing a detailed inspection, Rack Group was able to catch the problem early and implement corrective measures, ultimately saving the client substantial money in repairs and inventory loss.

Damaged Racking Upright

In addition, the warehouse experienced recurring issues with minor rack damage, which was causing repeated repair costs. Rack Group identified improper loading practices and uneven weight distribution as the root causes. We collaborated with the client's team to improve loading techniques and provided training to warehouse staff, which significantly reduced the frequency of damage incidents.

Racking Upright Damage Inspections

As a result, the client saw a substantial reduction in maintenance costs and a more efficient operation overall. This combined example shows how proactive maintenance, supported by regular inspections and targeted staff training, is essential for mitigating operational risks, preventing future issues, and ensuring that warehouses can maintain safe, uninterrupted operations while reducing long-term costs.

Beam End Connectors Damage Inspections

2. Partnering with Capita for a Seamless Warehouse Relocation

Rack Group also partnered with Capita for a large-scale warehouse relocation involving 14,000 pallet locations. Capita, an international business process outsourcing company, required a seamless relocation that would not disrupt their ongoing operations. Rack Group worked closely with Capita to plan the relocation, which involved evaluating six potential properties in the North-East of England and designing racking layouts to optimise storage space.

Capita 1

The relocation was conducted in four carefully planned phases over ten weeks, ensuring zero disruption to operations. Rack Group sourced and installed adjustable racking, while the stored items were transported gradually after each installation phase. Regular inspections were conducted throughout the relocation process to ensure every aspect of the installation met safety standards and remained free from damage. To further protect the new racking from vehicle impacts, barriers were installed to maintain racking integrity.

Capita 2

The project was delivered on time and within budget, with Rack Group providing a single point of contact for sourcing, installation, and ongoing inspections. This minimised complexity for Capita, allowing them to focus on other aspects of the move.

As Mary Collins, Head of Projects at Capita, noted, "Rack Group worked with us every step of the way, from layout design to planning, phasing, and installation. I would have no hesitation in recommending Rack Group for any size of project."

Rack Group, part of IWS Group, continues to support Capita with ongoing inspections and training. To maintain safety and compliance, it is recommended to inspect a warehouse every 6 to 12 months. According to the Health and Safety Executive (HSE), 135 workers were killed in work-related accidents in Great Britain during the 2022/23 period. Additionally, approximately 561,000 workers sustained self-reported non-fatal injuries in the workplace during the same timeframe. It is crucial to carry out weekly inspections of racking as well as annual reports through SEMA or PUWER-approved Inspectors. Book your next racking inspection with Rack Group.

The Rack Group Difference

These case studies highlight Rack Group's expertise in delivering comprehensive, tailored solutions that enhance safety, prevent costly damage, and support efficient warehouse operations through installation, relocation, and inspections. Whether it's preventing structural failures, improving operational practices, or managing a complex warehouse relocation, Rack Group delivers reliable, end-to-end support that drives results.

 

Why Choose Rack Group for Your Racking Inspections?

Over 40 Years of Expertise:

Rack Group brings over four decades of industry expertise, with some team members having been with us for 30 years and counting. This wealth of experience, combined with our history of operations, allows us to leverage our knowledge, resources, and industry-wide connections to benefit our customers. Our longevity in the industry demonstrates a commitment to quality and reliability that ensures our clients will always receive the best possible service.

SEMA and PUWER-accredited Inspectors:

Our inspectors are fully trained and certified to SEMA and PUWER accreditations, ensuring that our inspections meet the highest industry standards. These accreditations mean you can trust us to follow the best practices set out by the industry experts.

Complete Service Offering:

We provide full support for your racking needs, from inspections to repairs. Our comprehensive approach ensures all safety aspects are covered, reducing risks and improving reliability.

Customised Solutions:

We work with you to create a maintenance schedule that fits your facility's specific needs. Every warehouse is different, and our customised solutions address each facility's unique challenges.

Detailed Reporting:

Our reports give you actionable insights to solve problems quickly. These insights help guide future maintenance, contributing to better safety standards over time. Our comprehensive services also include consulting to help warehouse managers develop a long-term strategy for safety and efficiency. We don’t just offer one-off solutions — we build partnerships that last, offering support that evolves with your warehouse’s needs.

More Than Just Inspections: Full Warehouse Safety Solutions

In addition to racking inspections, Rack Group offers a full range of services to make your warehouse safer:

Inspections

Installations and Alternations

Maintenance and Repairs

We provide comprehensive racking inspections, carried out by our certified SEMA-approved Racking Inspectors (SARI), ensuring your warehouse systems comply with all safety and regulatory standards. Regular warehouse racking inspections help identify potential issues early, minimising the risk of damage, costly repairs, and operational downtime. Additionally, we can also offer PUWER-approved pallet racking inspections to ensure full compliance with health and safety requirements.

Our team can design, supply, install, and modify pallet racking systems to meet your specific operational needs. From initial setup to system alterations, we ensure that your warehouse storage solutions are optimised for safety, efficiency, and scalability. Whether it’s pallet racking, cantilever racking, drive-in racking, or mezzanine systems, we have the expertise to handle a variety of installations for all racking types tailored to your requirements.

We provide ongoing maintenance and repair services to keep your racking systems in top condition. Our proactive maintenance helps extend the lifespan of your equipment, while our repair services quickly address any damage to prevent disruptions.

Training

Impact Protection

Warehouse and Racking Accessories

Rack Group offers comprehensive training programs for warehouse staff, focusing on the proper maintenance, use, and safety of racking systems. Educating your team on best practices ensures safer operations and reduces the risk of avoidable damage or accidents. We provide a racking inspection course for warehouse staff so they know how to safely maintain and use racking systems. Racking inspection training is a crucial part of our approach, as it educates staff on the best practices for maintaining a safe warehouse environment.

We supply and install advanced impact protection solutions, including barriers, column guards, and rack protectors. These products are designed to minimise damage from forklifts and other warehouse vehicles, enhancing the overall safety of your racking systems.

We offer a variety of warehouse accessories such as load notices, column guards, and safety barriers. These accessories help to protect your racking infrastructure, improve efficiency, and maintain a safe working environment.

Schedule Your Racking Inspection Today

Don’t wait for an accident to highlight the need for racking maintenance. The risks of ignoring such an important part of warehouse safety are too great. Take a proactive approach by scheduling an inspection with Rack Group. Our expert team is here to help you protect your workers, safeguard your inventory, and ensure that you are meeting all safety standards. Choosing Rack Group means investing in a safer, more efficient future for your business.

Proactive safety is not just about compliance; it’s about making a commitment to operational excellence. With Rack Group, you can rest assured that your warehouse will meet and exceed the highest standards of safety, efficiency, and productivity. Let us help you take the next step towards a stronger, safer, and more resilient warehouse environment.

Contact us today to schedule your next racking inspection.

Discover More About Rack Group

Rack Group, as part of IWS Group, is driven by a commitment to safety, innovation, and customer satisfaction. Whether you need expert racking inspections or tailored safety solutions, Rack Group is your trusted partner for optimising warehouse operations.

We offer a comprehensive range of services, including pallet racking inspections, rack inspection services, racking inspection training, and a racking inspection course to ensure your warehouse remains compliant and efficient. Our expertise extends to installations and alterations, maintenance and repairs, training, impact protection, and warehouse and racking accessories.

Explore our services and products to ensure your racking systems meet the highest safety standards. View our case studies to see how we’ve helped businesses prevent costly disruptions and enhance operational safety. For the latest insights, check out our blog and contact us today to learn how Rack Group can support your warehouse safety needs.

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5 Essential Warehouse Safety Checks to Do Today

Check Your Warehouse for Safety Issues

Keeping your warehouse in tip-top shape is key to making sure everything runs smoothly and safely.

Regular safety checks of your racking can prevent accidents, boost efficiency, and save on costly repairs or downtime. If you spot any damage on your racking, report it to your Person Responsible for Racking Safety (PRRS) as soon as possible for them to take the appropriate action.

Emil Malczewski, our Trainer here at Rack Group, discusses five other important things you should check in your warehouse today:

1. Check for Weight Load Notices on Racking

Every run of racking in your warehouse should have a Weight Load Notice (a.k.a. Safe Working Load Sign). These signs let everyone know the maximum weight each section can safely hold. Here’s what to do:

  • Make them visible and readable: The signs should be easy to see and read.
  • Ensure they’re accurate: Double-check that the load capacities match your specific racking setup.
  • Keep them updated: If you’ve changed your racking or the types of goods stored, make sure the signs reflect that.
Rack Group Weight Load Notices

2. Inspect Beam End Connectors for Safety Locks

Each beam end connector in your racking system needs a beam safety lock or connector pin. This helps keep the beams securely in place. Here’s what to look for:

  • Make sure they’re there: Every beam end connector should have a safety lock or pin.
  • Use the right type: Ensure the pins are the correct ones for your racking type.
  • Check their condition: Look for any wear or damage and replace any worn-out locks or pins.
Rack Group Safety Locks

3. Ensure Racking Depth Matches Pallet Types

Your racking depth should match the types of pallets you’re storing to avoid overhang into aisles, which can be a safety hazard. Here’s a quick guide:

  • Chep Pallets: Usually 1000mm deep.
  • Euro Pallets: Typically 1200mm deep.

Most racking is set up at standard depths of 900mm or 1100mm. Make sure your racking depth fits the pallets you’re using to keep everything safe and tidy.

Rack Group Pallet Safety Awareness

4. Check Baseplates for Secure Bolting

Every baseplate in your racking system should be securely bolted to the ground. This keeps the uprights stable and prevents them from shifting. Here’s what to do:

  • Ensure at least one bolt: Each baseplate should have at least one bolt securing it.
  • Add more if needed: Some baseplates have 2 or more holes; use these extra holes if you have to re-install a bolt.
  • Regularly inspect: Look for any signs of movement or damage and secure or replace bolts and baseplates as needed.
Rack Group Baseplate Safety Awareness

5. Maintain Safe Clearance Above Stored Goods

To prevent accidents and ensure forklift safety, there should be a minimum clearance above your stored goods. Here’s the rule:

  • 75mm minimum: There should be at least 75mm between the top of the stored goods and the beam above.
  • Increase clearance with height: As the height of the stored goods increases, so should the clearance, since visibility from the ground decreases.

Regularly checking and maintaining this clearance helps prevent goods from being accidentally hit or damaged by forklifts.

Rack Group Racking Safety Awareness

Conclusion

Doing these simple safety checks as part of your regular racking inspection can make a big difference in keeping your warehouse safe and efficient. By checking weight load notices, ensuring safety locks are in place, matching racking depth to pallet types, securing baseplates, and maintaining safe clearance levels, you’ll create a safer working environment for everyone.

For more tips and training on racking safety, click here. Our racking safety training courses can help your team keep your warehouse racking safe and compliant.

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New Managing Director for Rack Group

IWS Group Announces Leadership Changes: Welcoming New Divisional Managing Director

In an exciting development, IWS Group is pleased to announce the appointment of Gary Coleman as the new Divisional Managing Director for both Brandsafe and Rack Group, effective June 12, 2024. This strategic move comes as part of an ongoing review of the IWS Group’s operating structure.

Gary Coleman brings a wealth of experience to the role, having spent over 18 years in the industrial sector, primarily with NENE Warehouse Solutions. During his tenure at NENE, Gary held several key positions, including National Account Manager and Managing Director, demonstrating his expertise and leadership capabilities.

Gary Coleman

Gary expressed his enthusiasm for the new role, stating, “I am thrilled to join the talented team at IWS Group. Together, we will work towards driving the business forward, enhancing our service offerings, and ensuring we provide exceptional value to our customers. I look forward to contributing to the growth and success of Rack Group and Brandsafe and am excited about the opportunities ahead.”

In conjunction with this appointment, Susy Keating has decided to step down from her role at Brandsafe after a decade of dedicated service. Susy's contributions have been instrumental in the growth and success of Brandsafe, and her decision to leave was made with careful consideration. She will remain with the company until the end of July, ensuring a smooth transition by working closely with Gary and her team.

"Over the past 10 years, Brandsafe has been a significant part of Susy's professional journey. Her commitment and dedication have been invaluable to both Brandsafe and the IWS Group," said Richard Harden, CEO of IWS Group. "We thank Susy for her remarkable service and wish her all the best in her future endeavours."

The operational, sales, installation, and finance structures within Brandsafe and Rack Group will remain unchanged, ensuring continuity and stability for our clients and partners.

Please join us in welcoming Gary Coleman to the IWS Group team. We are confident that his extensive experience and leadership will drive continued success for both Brandsafe and Rack Group.

About IWS Group

IWS Group is a family of market-leading product brands, manufacturers and service companies, providing essential services and supplies to the logistics, material handling and other industrial sectors across Europe and beyond.

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5 Easy Steps for a More Sustainable Warehouse

Five Ways To Make Your Warehouse More Sustainable

In the fast-paced world of warehousing, sustainability is emerging as a key priority for businesses looking to reduce their environmental footprint while improving efficiency and safety.

While grand initiatives like installing solar panels or implementing robotics and AI are commendable, there are smaller, more manageable steps that warehouses can take to reduce their ecological footprint. These steps not only contribute to a greener planet but also often result in cost savings and improved efficiency.

Here are five such steps that any warehouse can implement:

Rack Group Energy Efficiency

1. Optimise Warehouse Energy Consumption

One of the simplest yet most effective ways to enhance sustainability in the warehouse is by optimising energy consumption. Start by conducting an energy audit to identify areas of inefficiency.

Switching to energy-efficient lighting such as LED bulbs, installing motion sensors to control lighting, and ensuring equipment is powered down when not in use can significantly reduce energy consumption without requiring substantial investment.

Warehouse Sustainability Tips: Rack Group

2. Implement Waste Reduction Measures

Waste management is another area where warehouses can make significant strides towards sustainability.

Implementing a waste reduction strategy that focuses on recycling, composting, and minimising single-use plastics can drastically reduce the amount of waste sent to landfills.

Encouraging employees to use reusable containers for lunches and providing recycling bins throughout the facility are simple yet effective measures.

Racksack Rack Group Warehouse

3. Optimise Inventory Management

Effective inventory management not only improves efficiency but also contributes to sustainability efforts.

By optimising inventory levels and implementing just-in-time inventory practices, warehouses can minimise excess stock and reduce the need for storage space and transportation.

This not only reduces waste but also lowers energy consumption associated with storage and transportation activities.

Rack Group Warehouse Management System

4. Promote Sustainable Transportation Practices

Transportation is a significant contributor to carbon emissions in the supply chain. Warehouses can reduce their environmental impact by promoting sustainable transportation practices such as consolidating shipments, optimising delivery routes, and using fuel-efficient vehicles.

Additionally, investing in alternative fuel options or electric vehicles for transportation within the warehouse premises can further reduce emissions.

Rack Group Racking Maintenance Service

5. Invest in Proper Equipment Maintenance

Maintaining work equipment in good working order is not only crucial for operational efficiency but also for sustainability.

Regular maintenance ensures that equipment operates at peak performance, minimising energy consumption and reducing the likelihood of breakdowns.

By extending the lifespan of machinery and equipment, warehouses can decrease the need for frequent replacements, ultimately reducing waste and conserving resources.

Rack Group Warehouse Tips Transport

Rack Group: Your Partner in Sustainable Warehousing

When it comes to maintaining work equipment in optimal condition, Rack Group stands out as a leading specialist in supplying and maintaining racking equipment. With a focus on sustainability and longevity, Rack Group offers comprehensive services including installation, inspection, and repair of racking systems. Their team of experts not only ensures that your racking equipment is safe and efficient but also provides specialist training for your teams to inspect and repair racking in-house. By partnering with Rack Group, warehouses can take proactive steps towards sustainability while maximising the lifespan of their equipment and reducing repair bills in the long term.

 

In conclusion, sustainability in the warehouse is not solely about implementing large-scale initiatives but also about embracing small, manageable steps that collectively make a significant impact. By optimising energy consumption, reducing waste, maintaining equipment, optimising inventory management, and promoting sustainable transportation practices, warehouses can become more environmentally friendly, efficient, and cost-effective in their operations. Find out more here.

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Introducing Our New Head of Sales

Chris Rodger New Head Of Sales At Rack Group

Rack Group welcomes Chris Rodger to lead the sales team

We're delighted to announce the latest addition to our team: Chris Rodger, who joins us as our new Head of Sales. With over two decades of experience in the industrial workspace, particularly within the material handling sector, Chris brings a wealth of expertise to our company.

Here at Rack Group, we pride ourselves on delivering comprehensive racking solutions, encompassing design, installation, repair, and training services. With Chris on board, we're excited to further enhance our offerings and continue providing exceptional service to our valued clients.

Chris's extensive background in sales leadership, coupled with his deep understanding of our industry, positions him as a valuable asset to our team. His commitment to excellence aligns perfectly with our company values, and we're confident that his contributions will help drive our sales strategy forward.

Before joining Rack Group, Chris held prominent roles within the material handling sector, where he demonstrated a strong track record of driving growth and fostering strategic partnerships. We're thrilled to welcome him to our team and are eager to see the positive impact he will make.

"I am excited to join Rack Group and contribute to the company's continued success," said Chris Rodger. "Rack Group has a strong reputation for delivering top-notch solutions, and I look forward to leveraging my experience to further enhance our sales efforts and exceed customer expectations."

As part of the IWS Group, Rack Group remains dedicated to delivering innovative solutions and outstanding service to our clients. Chris's appointment reaffirms our commitment to excellence and our ongoing pursuit of customer satisfaction.

"We are delighted to welcome Chris to the Rack Group family," said Stuart Ovington, Managing Director at Rack Group. "His extensive experience and passion for delivering results will undoubtedly strengthen our sales team and reinforce our position as a leader in the racking industry. We look forward to the valuable contributions Chris will make as we continue to innovate and grow."

We're excited about the opportunities that lie ahead with Chris on board, and we look forward to the continued growth and success of Rack Group under his leadership.

Speak to a member of the team today.

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Rail Installation & Technical Services Ltd New Install

Optimising Warehouse Storage for RITS Logistics

Rack Group partnered with Rail Installation & Technical Services Ltd to design and install a tailored Link 51 pallet racking system, complete with Rack Armour® upright protection. The project maximised capacity, improved safety, and future-proofed their South West warehouse for growth.

Rack Group Lifecycle Email Image

Top 10 Racking Regulations for Warehouse Safety

Understanding and complying with racking regulations is essential for maintaining a safe, efficient and legally compliant warehouse. In this guide, Rack Group outlines the top 10 UK regulations every warehouse owner and site manager should know – helping you reduce risk, avoid costly damage, and protect your workforce.

Fully installed push-back racking system with four bays and three beam levels, ready for warehouse storage use.

Maximising Warehouse Efficiency

Discover how our racking installation and strategic relocation improved warehouse efficiency, maximised storage, and enhanced operational flow.

Rack Group Announces Lagerinnredning as New Distributor in Norway for Rack Armour®

Rack Armour DistributorSheffield, UK – 07 11 2023 – Rack Group, a leading provider of warehouse safety solutions, is thrilled to announce the expansion of its international distribution network through a new partnership with Lagerinnredning AS, a prominent Norwegian company specialising in warehouse optimisation and equipment.

This strategic alliance marks a significant milestone for Rack Group as it extends its reach into the Norwegian market, offering its state-of-the-art racking impact protection solutions to a broader audience. Lagerinnredning’s commitment to quality and customer service aligns with Rack Group’s mission to deliver unparalleled safety products to the warehousing and logistics industry.

“We are delighted to welcome Lagerinnredning into our family of distributors,” said Stuart Ovington, Managing Director of Rack Group. “Their deep understanding of the Norwegian market and dedication to delivering high-quality solutions make them the perfect partner to represent our Rack Armour® solutions. We are confident that this partnership will ensure Norwegian businesses have access to the best safety products to protect their staff and infrastructure.”

Tim Solsvik, Managing Director of Lagerinnredning AS, also expressed his enthusiasm for the partnership, stating, “It is with great pleasure that we join forces with Rack Group. Their innovative Rack Armour® complement our existing products and services perfectly, and we are excited to bring such a reputable brand to our customers in Norway. We believe that the combination of Rack Group’s expertise in warehouse safety solutions and our local market knowledge will result in a highly beneficial relationship for both parties and, most importantly, for our customers.”

Sushil Kumar, Regional Sales Manager of Rack Group said “We are very excited to work with Tim, and support Lagerinnredning AS with their ambitious growth plans, within the Norwegian market”

The collaboration is to start immediately, with Lagerinnredning AS ready to distribute Rack Armour®. The partnership is expected to improve the availability of premium safety solutions for Norwegian businesses and contribute to safer work environments across the region.

For more information about Rack Group and their Rack Armour® solutions, please visit www.therackgroup.com or www.lagerinnredning.no.

About Rack Group

Rack Group specializes in providing high-quality, durable safety solutions for the warehousing industry. With a focus on innovation and customer service, Rack Group has established itself as a leader in the field of warehouse safety, offering a wide range of products designed to protect both personnel and infrastructure including racking protection, bumper barriers and safety gates.

About Rack Armour®

Made from ballistics grade plastic, the Rack Armour® outer shell is shaped to divert impact energy around the rack leg instead of through it. Any remaining impact energy is absorbed by the interior foam until it is diffused. This twin action protection uniquely helps to maintain the structural integrity of the racking system.

Fitted in seconds and last for years, Rack Armour® requires no maintenance, and is rust and fade resistant. It is also fully recyclable and suitable for use in food production facilities.

For more information in becoming an international partner, please contact Sushil Kumar via email sushil@therackgroup.com or telephone +44 7708 326150

About Lagerinnredning AS

Lagerinnredning AS is a Norwegian company with a strong focus on warehouse optimization and equipment supply. Renowned for their expertise in creating efficient and safe storage environments, they offer a comprehensive range of products and services tailored to meet the unique needs of their customers.

IWS Group is Proud to Announce the Appointment of Richard Harden as the New Chief Executive Officer

IWS Group New CEO Richard Harden

Richard Harden is appointed as the new Chief Executive Officer of IWS Group. This strategic move is part of IWS Group’s commitment to fostering innovation and sustained growth, ensuring its continued leadership within the market.

With an extensive leadership background, Richard Harden brings a wealth of experience to IWS Group, having previously held CEO and MD positions at renowned companies such as Stuart Turner Ltd and WILO. Additionally, he served as President of the trade organization BPMA. Throughout his career, Richard has excelled in enhancing top-line growth for private equity-backed firms by forging strategic partnerships and implementing innovative sales and marketing strategies that have led to substantial growth milestones.

Under Richard’s capable leadership, a central focus will be on harnessing the collaborative strengths of IWS Group to provide customers in the industrial workspace with comprehensive, seamlessly integrated solutions. This approach aims to elevate customer satisfaction while reinforcing the overall impact and effectiveness of IWS Group’s offerings within the market.

Commenting on his new position, Richard said, “It’s clear IWS Group is a very ambitious company with a strong track record of organic and acquisition-driven success and a clear vision for growth, which is what attracted me to the position. The future of the group excites me, and I am delighted to lead it into its next phase of growth and innovation.”

“We’re extremely excited to have Richard on board as our new CEO,” said Neil Stephenson, Chief Financial Officer for IWS Group. “Richard’s extensive leadership background and his proven track record of accelerating market share aligns perfectly with our strategic vision for IWS Group. His dynamic leadership and innovative approach is just what we need to navigate the evolving market landscape and propel IWS Group to new heights. We look forward to the fresh perspective and the boundless energy he brings to our team, and we’re confident that under his leadership, IWS Group will continue to thrive and achieve great success.”

About IWS Group:

IWS Group is a family of market-leading product brands, manufacturers, and service companies that deliver essential services and supplies to the logistics, material handling, and various industrial sectors across Europe and beyond. The current IWS Group portfolio comprises Beaverswood®, Brandsafe, Rack Group, and Anco Storage, each of which contributes to the group’s enduring success.