Warehouse Racking Risk Assessment (UK)

What Employers Must Document & Inspect

Pallet racking is often treated as fixed infrastructure.

In reality, it is a work equipment system subject to legal safety duties.

If your warehouse stores goods on pallet racking, you are responsible for ensuring it is structurally sound, properly inspected, and supported by a documented risk assessment.

This guide explains what UK employers must assess, inspect, and record and how this fits within broader health and safety legislation.

Why Warehouse Racking Is a Legal Risk Area

Racking systems fail for predictable reasons:

  • Forklift impact damage
  • Overloading beyond design capacity
  • Poor floor anchoring
  • Missing beam locks or safety pins
  • Unauthorised modifications

Under the Health and Safety at Work Act 1974, employers have a duty to ensure workplace equipment does not pose a risk to employees or visitors.

Additionally, pallet racking systems fall under the Provision and Use of Work Equipment Regulations (PUWER)

This means racking must be:

  • Suitable for use
  • Maintained in safe condition
  • Inspected where deterioration could result in risk

Racking is not just shelving, it is load-bearing structural equipment.

Is a Warehouse Racking Risk Assessment Legally Required?

There is no standalone “Racking Act”.

However, under general HSE risk management guidance: https://www.hse.gov.uk/risk/

Employers must assess risks arising from work equipment and storage systems.

If pallet racking collapse or load failure is foreseeable, and it is, then it must be assessed and controlled.

In practice, that means your warehouse risk assessment should include:

  • Structural integrity of racking
  • Load capacity verification
  • Impact damage procedures
  • Inspection frequency
  • Traffic management controls

This is separate from but aligned with broader workplace safety systems.

What Should a Pallet Racking Risk Assessment Include?

A structured racking risk assessment typically covers:

1. Load Capacity & Configuration

  • Are load notices clearly displayed?
  • Is the racking used within its designed weight limits?
  • Has the configuration changed since installation?

If load notices are missing or unclear, the risk of overloading increases significantly. Properly specified pallet racking systems should always have clearly documented load ratings.

2. Upright & Beam Condition

  • Are uprights visibly damaged or twisted?
  • Are beams correctly seated and secured?
  • Are safety clips in place?

Even minor forklift impacts can compromise structural integrity. Routine warehouse racking safety checks should identify damage before it becomes critical.

3. Floor Fixings & Anchoring

  • Are base plates securely anchored?
  • Are bolts missing or loose?
  • Is the floor surface compromised?

Racking collapse often begins at ground level.

4. Traffic Management & Layout

  • Are forklift routes clearly defined?
  • Are uprights protected with column guards?
  • Is pedestrian separation adequate?

Poor layout design directly affects both safety and overall warehouse storage efficiency. Risk assessment should consider interaction between vehicles, loads, and structure.

5. Inspection & Documentation

  • Are inspections recorded?
  • Is damage categorised (Green/Amber/Red risk levels)?
  • Is there a defined escalation process?

This is where many warehouses fail.

How Often Should Warehouse Racking Be Inspected?

Best practice generally includes:

Weekly Visual Checks (In-House)

A nominated competent person should conduct documented visual inspections.

Annual Expert Inspection

Industry guidance from the Storage Equipment Manufacturers Association (SEMA)

https://www.sema.org.uk/ recommends a technically competent inspection at least once every 12 months.

After Impact Reassessment

Any significant forklift strike should trigger immediate review.

Inspection frequency should be proportionate to:

  • Traffic volume
  • Load weight
  • Environmental conditions
  • History of impact damage

Common Racking Safety Failures in UK Warehouses

Across industrial sites, recurring issues include:

  • Missing load notices
  • Mixing incompatible beam types
  • Unauthorised modifications
  • Ignoring “minor” upright damage
  • No documented inspection log

Compliance is not about reacting to collapse, it is about preventing foreseeable structural risk.

When Should You Replace or Upgrade Racking?

Consider review if:

  • Damage repairs are becoming frequent
  • Stock weight has increased
  • Layout changes have altered load distribution
  • Inspection reports identify recurring risk
  • Expansion has led to ad hoc configuration

As warehouse operations grow, racking must remain proportionate to operational demand.

Outdated or damaged systems may increase both safety risk and operational inefficiency.

FAQ: Warehouse Racking Risk Assessment

Is pallet racking covered under PUWER?

Yes. Racking systems are considered work equipment and must be suitable, maintained, and inspected under PUWER.

How often should warehouse racking be inspected?

Weekly visual checks and an annual competent inspection are widely accepted as good practice, though frequency should reflect risk level.

Do I need a SEMA inspector?

A technically competent inspection is recommended annually. Many employers choose SEMA-approved inspectors for assurance.

Who is responsible for racking safety?

The employer or duty holder responsible for the premises has legal responsibility for ensuring safe use and inspection.

Final Note

Warehouse racking risk assessment is not a paperwork exercise.

It is a structural safety responsibility.

Load capacity, inspection routines, damage management, and documented oversight demonstrate active control of foreseeable risk.

If you are reviewing your racking arrangements or unsure whether your inspection process aligns with current expectations, you can contact us