Rack Group’s Training Courses Achieve Prestigious Assured by RoSPA Qualifications

Rack Group, a leading name in innovative racking solutions, is thrilled to announce that our racking inspection and maintenance training courses have received the esteemed Assured by RoSPA Qualifications. This recognition signifies a remarkable achievement in our training courses to enhance workplace safety and to upskill internal teams to inspect and repair racking systems effectively.

Assured by RoSPA Qualifications, a nationally recognised Awarding Organisation, provides a stamp of assurance that our courses meet the highest standards in health and safety.

Stuart Ovington, Managing Director of Rack Group, expressed his enthusiasm about this accomplishment, stating, “We are delighted to receive the Assured by RoSPA Qualifications for our racking inspection and maintenance training courses. This recognition reflects our commitment to delivering top-notch training that not only enhances the skills of employees but also ensures the highest standards in safety and competence. This qualification is a testament to the quality and relevance of our training programs, ensuring that they are pitched at the appropriate level and delivered with excellence.”

Stuart also added that “Course Assurance from RoSPA Qualifications instils confidence in our stakeholders, including customers, employees, and partners, by guaranteeing that:

  • The course content contains relevant and up-to-date information.
  • The course is pitched at the appropriate level for effective learning.
  • The course meets high standards for trainer competence and overall quality.

The RoSPA Qualifications ‘stamp of assurance’ is a recognition of our commitment to delivering excellence in workplace safety.”

Rack Group remains dedicated to advancing workplace safety and empowering teams with the skills needed to maintain and enhance racking systems securely.


About Rack Group

Rack Group is a pioneering company specializing in racking solutions, offering innovative products and services to optimize warehouse spaces. With a focus on safety and efficiency, Rack Group designs, and installs racking systems and mezzanine floors and additionally racking inspection, maintenance, protection and training solutions, ensuring clients’ storage systems meet the highest standards and longest lifespan. Visit www.rackgroup.com for more information.

Rack Group training courses

Having the in-house personnel with the skills to quickly spot, assess and repair your racking, can have significant savings and improve safety and productivity. The Inspection course empowers internal teams to provide regular internal checks of racking to ensure it stays safe to support your stock and remains structurally sound. Our racking maintenance training, provides your team with the skills and knowledge required for them to safely carry out repairs on damaged racking systems with confidence.

About RoSPA Qualifications

RoSPA is a not-for-profit organisation that has worked for more than 100 years to help people recognise and reduce their risk of accidents, at home, on the road, at work and at leisure. Their goal is to enable everyone to live their lives to the full, safely. Visit About Us – RoSPA for more information.

The Main Reasons Behind Racking Collapse and How To Avoid These Risks

Warehouse safety is of paramount importance in any industrial setting. One critical aspect that demands attention is the integrity of racking systems.

Unfortunately, racking collapses can lead to catastrophic consequences, posing risks to personnel, operations and inventory. To prevent such disasters, let’s delve into the most common causes of racking failures, explore examples and most importantly the prevention of racking collapse.

Collapsed Racking Image Source TechRescueWMFS  Racking_collapses_1  Picture2


1. Racking Incorrectly Installed

One of the leading culprits behind racking collapses is improper installation. When racking systems aren’t assembled correctly, they lack the necessary stability to bear the weight they are designed for. Substandard installation often involves misaligned beams, loose connections, or insufficient anchoring to the floor or wall. 

Example: In a warehouse, a racking system was hastily installed without adhering to the manufacturer’s guidelines. As a result, the beams weren’t adequately secured, leading to an eventual collapse when the load capacity was exceeded. 


2. Overloaded Pallets and Beams

Either incorrect evaluation of weight limits or ignoring weight load notices. Pushing the limits of a racking system by overloading pallets and beams, is an invitation for disaster. Exceeding the maximum weight capacity compromises the structural integrity of the racking, increasing the risk of failure. 

Example: Even though the weight load notice stated the weight load capacity of the racking, pallets were stacked beyond the recommended load-bearing capacity of the racking. This constant overload weakened the system, eventually resulting in a catastrophic collapse. 


3. Impact from Material Handling Equipment

The bustling environment of a warehouse often involves the use of material handling equipment like forklifts and reach trucks. Accidents and collisions with racking systems can cause damage that goes unnoticed, and even small bumps will gradually weaken the structure over time. 

Example: A forklift operator accidentally backed into a rack, causing a slight dent in the upright. While seemingly minor, this impact weakened the racking’s structural integrity, leading to its eventual failure during regular operations by maxing its now weakened load potential or from further minor bumps. 


4. Racking Reconfigured and Not Re-Inspected for Safety

Warehouse dynamics change over time, prompting reconfigurations of racking systems. However, these alterations are not always followed by safety inspections. Neglecting to reevaluate the integrity of the racking after reconfiguration can lead to unforeseen vulnerabilities. 

Example: Due to an increase in new product lines, a warehouse decided to rearrange its racking layout. However, the safety inspection was overlooked, and the new configuration was never thoroughly assessed for structural soundness, eventually leading to a collapse. 


5. Racking Components Not Repaired Properly

When racking components sustain damage, repairs must be carried out promptly and professionally. Cutting corners or using makeshift fixes compromises the system’s overall strength and reliability. 

Example: In an attempt to save on costs, a warehouse maintenance team attempted to repair a bent beam by straightening it. This inadequate repair rendered the beam unstable, ultimately contributing to the racking collapse. 


How can you minimise the Risk of Racking Collapse? 

Qualified Installation, Maintenance, and Inspection Teams

The foundation of a robust racking system begins with a proper installation by qualified experts. Engaging professional installation teams ensures that racking systems are assembled in accordance with manufacturer guidelines, and following EN Regulations and SEMA Guidelines, to ensure the best structural integrity from the start. 

Proper installation ensures that racking systems can safely withstand the intended loads and daily operations. It encompasses aligning beams accurately, securely fastening components, and anchoring the racking securely to the floor or wall. 

Routine inspections involve comprehensive checks of the racking’s structural integrity, including uprights, beams, and connections. Inspections can be undertaken by an internal trained employee while annual inspections by external qualified inspectors. All annual inspectors should be trained to follow EN15635 Standard and PUWER Regulations, in identifying potential vulnerabilities and assessing load-bearing capabilities. 

Sufficient Training for Warehouse Teams

Empowering your warehouse teams with adequate training is a critical defence against racking collapse. Educating personnel on what to look for and the appropriate actions to take upon spotting an issue can prevent potential catastrophes. 

  • Comprehensive Awareness: Warehouse teams should be trained to recognize signs of wear, damage, or instability in the racking system. This includes understanding the importance of load limits, recognizing damaged components, and knowing when to report potential safety concerns. 
  • Immediate Action Plan: Training should equip personnel with a clear protocol to follow in the event they encounter a safety issue. Encouraging an open reporting culture ensures that any observed problems are promptly communicated to supervisors or maintenance teams for swift resolution. 
  • Ongoing Education: Safety training should be a continuous effort, ensuring that all personnel, including new hires, are well-informed about warehouse safety practices. Periodic refreshers and updates on industry best practices keep the workforce vigilant and informed. 

Infographic (3)In conclusion, mitigating the risk of racking collapse is a multi-faceted approach that relies on professional installation, regular maintenance, and diligent inspections. Equally important is providing thorough training to warehouse teams to recognize potential hazards and respond swiftly to ensure a safe and secure workplace environment. By implementing these strategies, warehouse managers can proactively protect their facility, personnel, and valuable inventory from the threat of racking failures. 

Rack Group have over 40 years’ experience in industrial pallet racking design, installation, repair and inspections, while providing training to upskill customer inhouse teams. Contact us for advice, and quotes for training, installations and inspections. 


What Does a Typical Rack Training Day Look Like

What Does a Typical Rack Training Day Look Like?

It’s better to be safe than sorry in every situation. Employees must have the knowledge and skills to handle the entire pallet rack life cycle, including set-up, annual inspections, equipment management, and maintenance.

Why Rack Training Is Important

Warehouses are dangerous places. Accidents happen, even with all the safety measures you can imagine. So, training your employees to recognise the dangers is crucial and identify problems—and address them before anybody gets hurt and before any valuable property gets destroyed.

Training can keep your employees safe, reducing the stress on everyone, leading to a happier, more productive environment.

New Training Centre Signage 2022
Inspections Rack Group Copy

A Breakdown of the Training Courses


These courses come in escalating levels and cover the knowledge needed for in-house racking inspections. The courses can be as short as two hours or as long three to six months, ending with special certifications. Here are some examples of what you’ll learn:

  • Racking types and components
  • Safe Working Load information
  • How to conduct a racking inspection
  • Allowable deflections and tolerances
  • Legal, moral and financial considerations

This ideal for team members involved in management and inspection or team members interested in inspecting industrial storage equipment.


This three to six month installation course ends with an Ofqual-regulated qualification, and covers the following modules:

  • Conforming to General Health, Safety and Welfare in the Workplace
  • Conforming to Productive Working Practices in the Workplace
  • Moving, Handling and Storing Resources in the Workplace
  • Installing Industrial Pallet Racking Systems in the Workplace
  • Installing Industrial Shelving Systems in the Workplace

This course is perfect for team members already working as an installer within the industry.

Installations Rack Group
Rack Group Training Courses Racking Maintenance

Damage and Repair

Much like our inspection courses, our Damage and Repair courses come in multiple levels according to level of complexity. They range in length from one day to three to six months. The courses focus on racking maintenance and repair of up to 12 meters depending on complexity. These courses generally cover:

  • Most commonly damaged components to racking
  • Upright and beam repairs
  • Legal issues associated with racking maintenance
  • Working at height safety

These courses are ideal for team members responsible for pallet racking maintenance and repairs. The damage and repair courses are also suitable for experienced maintenance teams working on higher level racking installations.


Our one-day course on pallet racking management covers planning and designing racking installations. It involves learning about the safe use of storage equipment on site. Some of the things you may learn about include:

  • Racking components
  • What to look for when carrying out regular checks and inspections
  • Racking structure user / operational requirements
  • Dos and don'ts around pallet racking

This course teaches you how to ensure your current system is built to the correct standards and is ideal for team members that oversee warehouse storage equipment safety.

Pallet Racking Training Rack Group


The right training can mean the difference between an accident that’s caught early and one that ends in tragedy. Ensure your team has the training to know what to look for.

Rack Group is the UK’s providers of warehouse racking solutions. Whether racking inspections, racking repairs, racking protection and racking training, our 40 years of experience in increasing safety whilst saving clients’ money is a testament to our commitment to get the job done right. If you want to commit your employees to a racking safety course, we can help. Get in touch with us today!

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Rack Group Training Courses Achieve Prestigious Assured By RoSPA Qualifications

Rack Group’s Training Courses Achieve Prestigious Assured by RoSPA Qualifications

Rack Group, is thrilled to announce that our racking inspection and maintenance training courses have received the esteemed Assured by RoSPA Qualifications.

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New Rack Training Centre Opens at Rack Group

Rack Group have opened a newly refurbished racking training centre in Barnsley’s Carlton Industrial Estate, only 6 miles from M1 Jct 38.

The refurbished centre enables candidates to undertake rack safety training away from their own warehouse site. This option is ideal for customers who have limited space on site, or who have extremely busy operations and therefore training on site is not an option.

The rack training centre is also ideal for companies who only have one or two candidates looking for rack safety training. These candidates can book onto one of our open training days at a time that suits them, offering a cost effective alternative to hosting a group training session at a customer site.

Larger groups are also able to book the training centre for team away days, where training can be incorporated as part of the day’s schedule.

New Training Centre Signage 2022
Training Centre Warehouse - Rack Group

Facilities at the centre include a large classroom and separate breakout room with private kitchen for lunch and refreshments. The centre also includes a designated training racking area where candidates will be trained to spot damage and safety issues within a real warehouse environment.

The full list of courses available at the Rack Training Centre include:

To register your interest in the Rack Training Open Days, or to enquire about a group booking, get in touch with the Rack Group team today.

Speak to a member of the team today.

What is EN 15635, and how is it related to storage equipment?

In 2008, the British Standards Institute adopted EN 15635 as the standard for the racking industry. This standard sets out how racking systems need to be installed and maintained. But what exactly is this EN 15635, and why is it so important?

What Is EN 15635?

EN 15635 became the standard with regards to the application and maintenance of steel racking systems. It acts as the guidelines of storage and racking systems to ensure safety on an operational level.

This is deemed necessary because a lot of these racking systems are used in close contact with heavy machinery. Not only does EN 15635 minimise any damage to the structure itself but it prevents safety risks to everyone within the vicinity.

It is important to note that EN 15635 is only used for racking and storage systems that are made of steel. Other racking and storage systems that are made of different materials may have different standards.

Dexion Wide Aisle Pallet Racking Rack Group
Installations Rack Group

Who Needs to Know and Comply with EN 15635?

This standard is very important to several industries. It is necessary for the manufacturers of storage equipment, specifically those who make items made of steel. This is crucial to them because it is the best way to demonstrate to end users that their equipment is safe to use.

Aside from the manufacturers, the designers and installers of racking layouts should also be aware of this standard. This way, whenever they are designing or installing any racking or storage system, they know that they are complying with the required standards.

Both manufacturers and suppliers of steel should also be familiar with EN 15635 as a precautionary safety measure. Of course, it lets them know that the quality of their steel is also passing the EN 15635 standards.

Why Do We Need to Use and Comply with EN 15635?

EN 15635 does not only include guidelines in the development and manufacturing of these storage systems. Rather, it also includes operational requirements, assembly and installation standards. These guidelines have been created for the purpose of safety and have been considered to be a top standard.

EN 15635 ensures the safety of operations when using these storage systems. It also addresses any possible issues and helps classify them while at the same time providing the recommended solutions. This provides ease when it comes to dealing with any safety issues with regards to the storage systems that are being used.

This has also helped in improving the quality of the steel itself and its manufacturing process. This has ensured that the racking systems and storage solutions remain of the highest quality possible to endure any tough conditions.

AR Racking Supplied By Rack Group UK
PSS Stronglock Racking Supplied By Rack Group UK

What Happens If We Do Not Comply with EN 15635?

While it is possible to get away without complying with EN 15635, it poses a risk of a safety hazard, harm, damage in operations and possible human safety being compromised. The standards exist for a valid reason.

So even if it is possible to avoid complying with EN 15635, this does not mean you should. The existence of the standard means that there is an importance to it that should be followed.

If an incident was to occur that involved the safety of the racking system, the Health and Safety Executive would investigate the business owner. The company would then need to demonstrate the steps they took to avoid the incident. Following the EN 15636 standard is the best way companies can ensure they are doing all they can to keep their warehouse safe.


EN 15635 is important in that it has been created to ensure the safety of the facilities, equipment, and operators. All of this is done while providing solutions that are efficient. It is important that you are familiar with these standards and ensure that your storage systems also comply.

If you are seeking industrial racking services, including the supply and installation of storage systems, you can contact Rack Group. We are a reliable provider of racking solutions for warehouses and have been in operation for 40 years where our priority is your safety. Contact us to learn more.

Speak to a member of the team today.

5 Ways to prolong the life of your racking

5 Ways To Prolong The Life Of Your Racking

How to prolong the life of your racking

Let’s face it, storage equipment doesn’t come cheap. Racking plays an essential role in keeping your warehouse operational, yet can also be the reason why you encounter disruptions and down time. This article delves into some of the ways you can get the most out of your racking, ensuring it lasts for years to come.

Racking has a very important job to do. Storage equipment is designed to hold tremendous amounts of warehouse stock. This stock is precious, as are your people who work in and around it. It’s also a huge investment for your business. Whether you choose to buy brand new, or source some quality second-hand systems, you’ll want to prolong the life of your racking for as long as possible to get a good ROI.

If well maintained, industrial storage equipment can last for years and years. This of course depends on how busy your warehouse is, the types of products you are storing, and the environment your racking is stored. It also depends on how well you treat it.

This brings us to our first tip on how to prolong the life of your racking:

1. Make sure your warehouse operators are fully (and regularly) trained

This may sound obvious but the main source of damage to racking is due to impact from Material Handling Equipment such as forklift trucks. This seems like a sensible place to start when looking at ways to prolong the life of your storage equipment. Ensure your teams are not only trained when they join your company, but have regular refresher training to keep their skills sharp.

It’s also important to ensure your team is confident working with the racking itself. One example could be with the weight load limits on your particular type of pallet racking. Displaying weight load notices at the end of every aisle of racking enables your team to quickly check limits and ensure they are followed. Overloading racking, or storing pallets with uneven distribution of weights is one way storage systems can be weakened, potentially leading to racking collapse.

So, you’ve had your racking installed by a top-notch team of qualified installers, your MHE drivers are fully trained and your stock is safely loaded. It’s now time to talk about protecting that lovely new racking installation of yours. As the classic saying goes, prevention is cheaper than the cure. Which brings us to tip number two:

Installations Rack Group
Rack Armour Racking Protection

2. Protect racking uprights before damage occurs with guards

Whether you prefer metal guards, or hard-wearing polymer guards, choosing to protect your racking uprights will save you money in the long-run. Guards can cost as little as £10 each, protecting the most vulnerable part of the upright. In comparison, a full upright replacement can cost up to £500.

Racking upright guards can perform for many years, being replaced only when repeated or major impact has occurred, making them a cost-effective option. Not only do they protect the upright from most types of impact damage, they also act as a visual deterrent to MHE operators. Usually sold in bright yellow colours, the upright guards signal a hazard to drivers whilst they move around the warehouse.

There are also other types of protection systems you can utilise to prolong the life of your racking, which brings us to tip number three:

3. Install racking protection barriers in high-risk zones

The end of racking aisles can be particularly vulnerable areas for racking damage. Warehouse vehicles will often turn tightly down aisles, causing impact to occur. Our next tip to prolong your racking involves installing impact protection barriers in these high-risk zones.

End of aisle barriers absorb and deflect impact, and come in all sorts of styles and materials. Choose the best option for your warehouse depending on the type of vehicles in operation and the type of racking you have. You should also factor in the amount of maintenance that might be required for certain types of barriers. If contact occurs with painted metal barriers, for example, the barriers will require frequent re-painting to ensure they remain highly visible and keeps your warehouse looking clean and tidy.

With your barriers and guards in place, it’s now time for tip number four:

Rack End Barrier Rack Group
Inspections Rack Group

4. Regularly inspect your racking for signs of damage or safety issues

UK guidelines recommend employers conduct regular and annual racking safety inspections. By checking over racking regularly, and reporting damage straightaway, you’re not only meeting these guidelines, but you’re also helping to prolong the life of your racking.

In busy warehouses, frequent little knocks to racking can go unnoticed. Large pallets of stock can also obscure some areas of damage. Ensuring your team routinely checks over your racking for defects means any potential issues can be flagged and action can be taken. This might be to unload the racking bay and carry out urgent repair work, which leads us into our final tip:

5. Repair damage to racking quickly to reduce serious consequences

The level of damage to racking uprights, bracing or beams is often categorised as a traffic light system by SEMA. Green signals that the damage should be monitored but no immediate action is required. Amber risk signals a hazard that requires action as soon as possible. Damaged categorised as a red risk requires immediate action as the damage is considered very serious.

The level of damage will prioritise which repair work needs to be carried out first. Staying on top of repair and maintenance work will help reduce repair bills long-term as some green or amber hazards may develop into red risk hazards, which are more costly than smaller repairs. Ignoring repair work won’t make the damage go away. Make sure you’re taking all the steps to prevent catastrophic accidents involving collapsed racking, and prolong your racking for as long as possible.

Racking Repairs & Maintenance Rack Group

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Is your warehouse 100% safe? Webinar

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The Ultimate Guide to Racking Safety Audits

This is where the safety Webinar on ‘Is Your Warehouse 100% Safe? The Ultimate Guide to Racking Safety Audits’ will take place - at 2pm on 18th May 2022!

Has auditing become a lengthy, over-complicated process?

Graeme Waller, (Training Manager at Rack Group,) and Kirsty Rogers, (Managing Director at Specialist Industrials Ltd,) will discuss how to organise, plan and successfully execute your warehouse safety audit - making audits faster and easier.

This Webinar supplies all the need-to-know basics in just a 30 minute live conference, complete with a live Q&A so you can speak directly to the experts about your specific issues.

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UK legislation: Racking and Storage Equipment Inspections

The UK has numerous safety standards regarding racking and storage equipment inspections. Due to the complexity of statutory law and guidance, companies often get confused by what the legal requirements actually are.

We aim to make things simple by breaking down what you need to know.

Firstly, companies have a general duty for the health and safety of their employees.

“It shall be the duty of every employer to ensure, so far as is reasonably practicable, the health, safety and welfare at work of all his employees.”
(Health and Safety at Work etc. Act 1974, section 2)

Rack Training Damage Inspection
Rack Group Racking Safety Inspection Training

Secondly, racking, or any storage system, is considered work equipment and therefore needs to be well maintained.

“Every employer shall ensure that work equipment is maintained in an efficient state, in efficient working order and in good repair.”

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

To ensure your racking is well maintained, regular inspections are recommended to identify any damage quickly so that repairs can be carried out.

“Every employer shall ensure that work equipment exposed to conditions causing deterioration which is liable to result in dangerous situations is inspected”

  • At suitable intervals; and
  • Each time that exceptional circumstances which are liable to jeopardise the safety of the work equipment have occurred
  • To ensure that health and safety conditions are maintained, and that any deterioration can be detected and remedied in good time.” (PUWER 1998, regulation 6)

Environments where forklift trucks and other MHE (Material Handling Equipment) operate can pose a risk to racking when impact occurs. Damaged uprights can cause total collapse of racking systems and often leads to serious injury.

“A technically competent person shall carry out inspections at intervals of not more that 12 months. A written report shall be submitted to the PRSES [Person Responsible for Storage Equipment Safety] with observations and proposals for any action necessary.” (BS EN15635, Expert inspections)

Regular inspections should therefore be carried out to identify any damage as early as possible to prevent accidents. You should also have your racking inspected by an expert at least once a year.

Warehouse Training Rack Group

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