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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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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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.

END

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 to Look for in a Warehouse Racking Inspector

A racking inspection is crucial to maintain a safe and efficient workspace, but it is something that can be easily overlooked. Without regular inspections, warehouse racking can pose serious safety hazards, leading to injury and inventory damage. That’s why inspection consultations are crucial for any business that uses warehouse racking.

The Rack Group has written this piece to discuss what makes an effective racking inspection, why it matters, regulations, and how it can benefit your business. So, whether you’re looking to undertake your own inspections or want to understand how to choose a third-party inspection service, keep reading for our expert insights.

Pallet Racking Training Rack Group

Understanding SEMA and why it matters for warehouse inspections

For warehouse racking inspections one organisation stands out as a recognized authority on safety and quality: the Storage Equipment Manufacturers’ Association, or SEMA.

SEMA is a UK-based trade organisation that represents manufacturers and suppliers of storage equipment, including racking and shelving systems.

So why does SEMA matter when it comes to inspections? For one, SEMA-approved inspectors have access to the latest industry knowledge and adhere to strict safety standards, ensuring that their inspections are thorough, accurate, and effective. In the eyes of HSE it makes them the ‘Technically Competent” person who might be a trained specialist within an organisation, a specialist from a racking supplier, or an independent qualified rack inspector.

If you’re looking for an effective racking inspection, we highly recommend choosing a SEMA-approved inspector, to have confidence in the safety and quality of your warehouse racking.

The importance of HSE guidelines for warehouse inspections

Another crucial factor when choosing a racking inspector is adherence to HSE (Health and Safety Executive) guidelines for warehouse safety and inspections. HSE is the UK government agency responsible for promoting and enforcing workplace safety, including warehouse operations.

Following HSE guidelines for racking inspections can have numerous benefits for businesses. For one, it helps businesses maintain compliance with government regulations, avoiding potential fines and penalties as well as injury and fatalities.

Following HSE guidelines helps with record-keeping and documentation, which can be crucial in the event of an accident or liability claim.

When choosing a racking inspector, it’s important to ensure that they are accredited and follow HSE guidelines for safety and inspections. Familiarising yourself with these guidelines can also help you identify potential safety hazards and ensure that your warehouse is as safe as possible.

What to expect from a racking inspection and inspector

Inspections are designed to help prolong the lifespan of your racking systems by identifying any signs of wear and tear or damage that could compromise safety or performance. Addressing these issues early, it can help you avoid costly repairs or replacements down the line.

In addition to the cost savings associated with identifying potential risks early, inspections can also help you reduce liability and claims. By ensuring that your racking systems are safe and compliant with the latest health and safety legislation, you can protect your business from costly claims and legal fees.

An inspection process begins with a visual inspection of your storage systems, during which the inspector will look for any signs of damage, wear, and tear if it meets with the original manufactures design and build standards, or other issues that could compromise safety. They will also check that your systems are in compliance with the latest health and safety legislation, including HSE regulations.

Once completed the inspector should provide you with a detailed report outlining any issues identified and recommendations for how to address them using the SEMA/PUWER/EN15635 Red, Amber, and Green classifications. Sometimes this report can be overwhelming or confusing, which is why a good inspector will take the time to walk you through any identified situations in the report. The inspector should want to ensure that you have all the information you need to make informed decisions about how to address any issues and ensure the safety and compliance of your storage systems.

According to SEMA, after an annual racking inspection, a warehouse racking inspector should provide the following:

Detailed report: The inspector should provide a detailed report outlining the findings of the inspection. The report should include a description of any damage or defects found in the racking system, as well as recommendations for repairs or replacements.

Risk assessment: The inspector should provide a risk assessment that evaluates the safety of the racking system. The risk assessment should identify any potential hazards or risks associated with the racking system and recommend measures to mitigate those risks.

  • SEMA’s RAG classifications are used to assess the severity of damage or defects found during a racking inspection. Here’s a breakdown of the classifications and their corresponding Priority rated actions:
  • RED RISK – Areas where a high level of damage is identified of over twice the SEMA limits. This warrants immediate offloading and isolation of the affected area until repair work is carried out
  • AMBER RISK – Areas where the damage identified is greater than the SEMA limits. This warrants remedial work to be carried out. However, the damage is not sufficiently severe to warrant the immediate offloading of the area. No additional loads shall be placed in the affected area and, once the pallet positions in this area are emptied, they should not be refilled until the repairs are carried out. If repairs are not carried out within 4 weeks, an Amber risk item automatically becomes a Red risk item
  • GREEN RISK – Areas where damage is present, however, the level of damage is within the SEMA limits and should be recorded for further consideration at the next inspection

By using the RAG classifications and corresponding Priority rated actions, it aims to help you and racking inspectors prioritize and address any safety issues identified during an annual racking inspection. This ensures that any urgent risks are addressed immediately and that less urgent issues are addressed in a timely manner, reducing the risk of accidents and maintaining a safe working environment.

A good inspection company should go beyond just the inspection process and identifying issues, to provide support throughout the inspection process and beyond. Any inspector’s goal is to help you create a safer and more efficient warehouse environment that can help you reduce or eliminate repetitive damage, claims, and liability.

How to choose a racking inspection provider

Now that we’ve discussed the importance of racking inspections and what makes an effective inspector, how do you go about choosing a racking inspection provider? Here are some key factors to consider:

  1. Experience: Look for an inspector or provider with a proven track record of conducting effective and thorough inspections. Ask about their experience working with businesses similar to yours and ask for references if necessary.
  2. Qualifications: In addition to experience, look for a provider with relevant qualifications and certifications. For example, inspectors who are members of SEMA (Storage Equipment Manufacturers’ Association) are held to high standards of safety and quality.
  3. Reputation: Do some research on potential providers to see what their reputation is like in the industry. Look for reviews and testimonials from previous clients and ask for references if necessary.
  4. Cost: Of course, cost is an important factor to consider as well. However, don’t make cost your only consideration when choosing a provider. Remember that investing in a quality inspection can save you money in the long run by reducing the risk of accidents and associated costs.

When choosing a racking inspection provider, it’s important to take the time to research potential options carefully. Don’t be afraid to ask questions and seek out references to ensure that you’re making an informed decision based on your needs and budget. By choosing a qualified and safety-conscious provider, you can protect your employees, inventory, and bottom line.

When should I have racking inspected?

The frequency of pallet racking inspections required depends on a variety of factors that are particular to your site but, typically, the first inspection should be carried out within 6 months of the installation becoming operational and at least annually from then on.

PUWER is a set of regulations that apply to work equipment, including racking systems used in warehouses. The regulations require that all work equipment, including racking systems, has not deteriorated through use.

Under PUWER, warehouse racking systems must be inspected at regular intervals to ensure they remain safe for use. The frequency of inspections will depend on a number of factors, including the type of racking system, number of pallet movements, age of the system, previous damage recorded, type of system even new FLT operators and the level of risk associated with the racking system.

Finding an inspection partner with industry experience and commitment to cost savings!

At Rack Group, our inspectors don’t just identify issues but work with our clients to help address and stop issues from reoccurring.

We’re proud to draw on our 40 years of experience in the racking industry and to provide top-quality inspection services that help our clients save money and reduce risk. We’ve seen it all when it comes to racking systems, and our experience enables us to identify potential risks and issues before they become costly problems.

Our experienced qualified inspectors will walk you around any identified situations in the report, to spend the time to assist you with the information you need to ensure your storage systems are safe and compliant with the latest health and safety legislation. A large part of what we do is guidance on how and why issues occur, the action required to rectify them, and more importantly the actions needed to stop them from reoccurring. This further helps reduce risk and prolong the lifespan of your racking…ultimately saving you money!

On completion of our electronic inspection from our PUWER and SEMA accredited team you will have a clear and concise digital next day report, highlighting;

  • Priority-rated actions to SEMA’s Red, Amber, and Green classifications
  • Recommendations that will prolong the life of your storage equipment
  • Guidance to improve workforce safety such as housekeeping

Our services go that extra mile to provide a comprehensive, friendly, and tailored service which has seen us become the pallet racking inspection company of choice, for many recognisable names within the UK and Ireland.

Our commitment to cost savings and risk reduction is just one of the many reasons why businesses trust us to provide top-quality inspection services. If you’re interested in learning more about how we can help you save money and reduce risk, please don’t hesitate to contact us to schedule an inspection. The Rack Group looks forward to working with you.

If you have any questions about our services or products, please contact The Rack Group over the phone at +44 (0)1226 784488 or email via info@therackgroup.com. 

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Rack Group Racking Inspection Kit

The Importance of Regular Pallet Rack Safety Inspections

Regular examination and repair of pallet racking and shelving are essential to warehouse management. If storage systems are neglected, warehouse and operational managers may be unaware of the hazards to operations, workers, and goods.

Failure to conduct frequent visual inspections, an annual rack inspection by a technically competent person, or a replacement of any damaged components may result in legal liabilities in the unfortunate case of an accident.

Here are the facts about the importance of rack inspection:

The Importance of Annual Rack Inspection

The European standard EN 15635 Steel Static Storage Systems - Application and Maintenance of Storage Equipment describes pallet rack safety regulations regarding inspections and repair.

Section 9.4.2.3 Expert Inspections indicates that inspections should be conducted by technically competent persons every 12 months. A report with observations and recommendations for any necessary action must be presented to the person responsible for storage equipment safety (PRSES).

Rack Training Damage Inspection
Rack Group Training And Inspections

Making Regular Visual Inspections

According to EN 15635 part 9.4.2.2 Visual Inspections, besides the annual pallet racking inspection, the PRSES should ensure that checks are carried out at weekly or different regular intervals based on a risk assessment. A proper written record must be kept.

Section 9.4.1 states that storage equipment should be examined regularly for safety and especially for any damage that has occurred. Repairs must be completed promptly and effectively, with proper attention to the system's continued safety. All damage or other incidents must be documented.

Differences between Visual Inspections and Annual Inspections

Visual inspections and the regulated annual inspections are not the same. While it is entirely possible for your staff to perform weekly visual checks, yearly inspections are better handed to professional inspectors.

They can assist you in educating your personnel in charge of the visual inspections. A technically qualified individual should perform annual checks, so leave it to the specialists and contact us immediately.

What Happens When Damaged Racking Is Found?

Any damage to racking/shelving compromising safety must be repaired quickly, according to the criteria of the Employer's Liability Insurance Association and the Standard EN 15635.

This is true whether the damage is discovered by the fork truck driver, the storage installation manager, or the Association-approved racking and shelving inspector.

Follow these steps:

  • Damage must be reported to the safety officer as soon as it is discovered.
  • Implement safety-related measures.
  • A written report with the responsibility to preserve must be produced.
  • If the same damage occurs repeatedly, the reason should be investigated.
  • Begin a damage control method in line with EN 15635, Section 9.4.5.
Upright Damage Rack Group
Racking Maintenance Rack Group

Replacing with Original Spare Parts

Any damaged components should be replaced instead of repaired. According to Section 9.7.1 of EN 15635, damaged components should not be fixed since effective quality control of cold-reduced parts is extremely difficult. Repair of damaged parts is not permitted unless authorised by the equipment provider.

The EN 15635 Section 7 also mentions that the loading capacity may be affected when racking or shelf installation is modified. All changes must be approved by the supplier or a competent professional. Any advice must be followed before any changes are made. Changes must be made in line with the supplier's instructions.

Conclusion

Racking is essential to any warehouse facility, and its quality must be scrutinised regularly. This will help ensure safe and high-quality storage.

Are you in need of pallet rack inspection services in the UK? Rack Group provides warehouse racking solutions, inspections, repairs, protection, and training. Give us a call to learn more!

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.

Conclusion

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.