Identifying Racking Damage & Repair Protocols

Racking damage can compromise safety and reduce capacity. Here’s what to look out for, how damage is categorised, and what should happen next. Judging whether damage is acceptable is a job for a competent inspector, so the most important step for everyone else is to report it straight away.

Common Damage Types

Beams

Beams can be bent, twisted or dented by impacts from forklifts or loads. Beams naturally deflect under load, which isn't the same as damage: what matters is permanent deformation when the beam is unloaded. Whether it's acceptable depends on the span, the direction and nature of the deformation, and the manufacturer's requirements.

A beam assessed as unfit for service is normally replaced. Any repair to the component itself must be authorised by the manufacturer and follow its procedure, and bent components should never be straightened using heat.

Beam Connectors & Locks

Bent or cracked beam-end connectors, damaged upright slots and missing or damaged locking devices all weaken the connection between beam and upright. Visibly deformed connectors must be unloaded and the supplier's advice sought. A damaged welded connector normally means replacing the complete beam assembly, not cutting off the connector and fitting a new one on site.

Uprights

Uprights can be bent, dented or buckled by impacts or overloading. Buckling is a serious structural concern. Isolate the affected racking, arrange for it to be offloaded safely and get a competent assessment. Don't assume that lower levels, or neighbouring bays sharing the damaged frame, are still safe to use.

Bracing, Baseplates & Anchors

Damaged or missing frame bracing, bent baseplates and loose or missing floor anchors all reduce the stability of the racking. Report and assess them like any other damage.

Corrosion

Rust should be assessed for pitting, loss of section and its effect on connections and baseplates. How significant it is depends on the original thickness of the component, where the rust is and how far it has spread.

Green, Amber and Red Damage

SEMA's inspection guidance sorts damage into three categories. The category is assigned through competent assessment, not judged from a single measurement.

Putting Damage Right

Replacing damaged components is the usual way of repairing racking. Components assessed as unfit for service should be replaced with the correct, manufacturer-approved parts. Cosmetic damage to the paint or coating may only need treatment or monitoring.

Several damaged components don't automatically mean a whole bay must be replaced, although extensive damage may make that the right option. The remedial work should match the actual extent of the damage.

Upright Cut-and-Replace Repairs

Some repairs cut out a damaged section of upright and splice in a new piece. SEMA does not advise this as an acceptable alteration, and recommends replacing damaged components with new parts from the original equipment manufacturer.

Repair work should be carried out by trained installers, with competent completion checks and a documented handover. The manufacturer or an engineer should be involved where required.

Person Responsible for Racking Safety

Every site with racking should nominate a Person Responsible for Racking Safety (PRRS), as recommended in HSE guidance (HSG76) and SEMA's codes of practice. They are the named contact for anything to do with racking, and they:

• receive damage reports and make sure the affected area is made safe
• arrange regular visual inspections, and an expert inspection at least once every 12 months
• make sure remedial work is completed within the required timescales
• keep inspection, damage and repair records up to date
• make sure load notices are displayed and staff understand them
• control any changes to the racking layout or use

Everyone who works around racking should know who the PRRS is and how to report damage to them.

Documentation

Keep a record of every defect and how it was dealt with:

• Exact location of the damage, the date, photographs and the assessed risk
• Any immediate restrictions put in place, and who was notified
• Components replaced, including the manufacturer and specification
• Installer details, completion checks and handover
• Closure of the defect in the inspection records by the person responsible for racking safety

If an approved change affects the racking's configuration or capacity, update the load notices and supporting design information, with the revised limits established before the change is made. Replacing a damaged part with the correct equivalent component doesn't, on its own, need a new capacity assessment.