Racking Maintenance Schedules & Best Practices
Regular inspection and maintenance help keep racking safe, support your health and safety obligations and reduce avoidable downtime. This guide sets out the inspection schedule recommended in SEMA's guidance, and good maintenance practice in between.
Inspection Schedule
| Frequency | Inspection or Action | Responsibility | Main Focus |
|---|---|---|---|
| Immediately when damage or a concern is noticed | Report the issue and take appropriate protective action | All warehouse staff report to the Person Responsible for Racking Safety (PRRS) | Impact damage, displaced components, unstable loads and other safety concerns |
| Weekly, or another interval justified by risk assessment | Documented visual inspection | Suitably trained person, coordinated by the PRRS | Condition, correct use, load notices, pallet positioning, protection and outstanding defects |
| At intervals not exceeding 12 months; sooner where appropriate | Expert inspection and written report | Technically competent person, such as a SEMA Approved Rack Inspector (SARI) | Racking condition, configuration, operational safety and recommendations |
| Following an impact or incident that may affect safety | Prompt assessment before affected racking returns to service | Competent person with expertise appropriate to the issue | Extent of damage, isolation, safe offloading and necessary remedial work |
A monthly walk-round by a manager can be a useful extra check, but it doesn't replace the documented weekly visual inspection.
What the Expert Inspection Covers
An expert inspection looks at the racking's condition, its configuration and how it's being used, and produces a written report with recommendations. It doesn't automatically include structural calculations, proof load testing or confirming the capacity of racking whose loads are unknown. Those are separate engineering assessments, arranged when needed.
Good Maintenance Practice
Corrosion & Environment
Keep racking clean and dry, and remove dust, debris and spills that trap moisture. In damp, coastal or chemical environments, use a racking system and protective finish specified by your supplier for those conditions. Existing corrosion needs assessing: painting over it doesn't restore lost material or capacity.
Connections & Anchors
Include visible connection and anchor defects, such as loose bolts or anchors, in your routine checks, and don't wait for the annual inspection if you find something loose. Any tightening, torque checks or replacement should follow the manufacturer's instructions and be carried out by appropriately trained people. Fasteners, washers and locking arrangements should be the ones specified for your system; don't add products or change the assembly without the manufacturer's approval.
Load Positioning
Incorrect load positioning or distribution can overload individual components or introduce loading conditions outside the design assumptions. Make sure staff follow the load notice and the specified pallet arrangement, and check regularly that goods are being stored the way they should be.
Tracking Defects
Track every defect through to completion: its location, risk category (green, amber or red), any restrictions put in place, repair dates and completion checks. Repeated damage in the same place should trigger a review of the cause, such as handling practices, clearances or inadequate protection.
Changes & Records
Approve any change to the racking's configuration or capacity before the work is done, then update the load notices and supporting records. Replacing a damaged part with the correct equivalent component doesn't, on its own, need a new capacity assessment. Keep records of all repairs and modifications for audits and insurance.
Service Life
There's no single lifespan for racking. How long it lasts depends on its condition, environment, loading, handling and maintenance, and properly specified and maintained racking can give decades of service. Key factors:
- Regular inspection, with prompt assessment and appropriate action on damage
- Managing corrosion and keeping racking clean and dry
- Staff training in safe load placement and equipment handling
- Planned maintenance rather than waiting for things to break
Racking Maintenance Programme
Our maintenance programme supports your own ongoing safety management. Annual expert inspections, maintenance advice and arranged repairs work alongside your routine checks and immediate damage reporting, to keep your racking safe for years to come.
Set Up Maintenance Programme