HOW TO PASS A PALLET RACKING INSPECTION
Published 1 March 2026 · 9 min read
A pallet racking inspection isn't something to dread — it's an opportunity to verify that your warehouse storage is safe, compliant, and performing as it should. With the right preparation, passing an inspection is straightforward.
At UM Storage Systems, our inspectors have assessed thousands of racking installations across the UK. In this guide, we share exactly what inspectors look for and the steps you can take to ensure your racking passes with flying colours.
WHY RACKING INSPECTIONS MATTER
Racking collapses are among the most serious warehouse accidents. They can cause fatalities, life-changing injuries, and catastrophic stock losses. The HSE takes racking safety extremely seriously — and so should every warehouse operator.
Regular inspections catch problems early, before minor damage becomes a structural failure. They also demonstrate to the HSE, your insurers, and your employees that you take safety seriously.
8 STEPS TO PASS YOUR RACKING INSPECTION
Appoint Your PRRS
Designate a Person Responsible for Racking Safety within your organisation. This person should be trained to conduct weekly visual checks and understand the damage reporting process.
Implement Weekly Visual Checks
Your PRRS should walk the warehouse weekly, checking for visible damage to uprights, beams, and base plates. Use a standardised checklist and record all findings — even if nothing is found.
Display Correct Load Notices
Every run of racking must display a load notice showing the maximum permissible loads per bay and per beam level. These must match the actual racking configuration — if you change beam positions, update the notices.
Report and Classify All Damage
Use the green/amber/red traffic light system defined in EN 15635. Green items are monitored, amber items require action within 4 weeks, and red items demand immediate offloading and isolation.
Book an Annual Expert Inspection
Arrange a thorough inspection by a competent external inspector at least once every 12 months. High-traffic warehouses or sites with frequent forklift damage may benefit from six-monthly inspections.
Act on Inspection Findings Promptly
Don't file the report and forget it. Create an action plan for all amber and red items with deadlines and assigned responsibility. Red items must be addressed immediately — there is no grace period.
Maintain Complete Records
Keep all inspection reports, damage logs, repair records, and load calculations in an accessible file. The HSE may request these during a visit, and they demonstrate your commitment to compliance.
Use Qualified Professionals for Repairs
Never attempt to straighten bent components or modify racking without professional guidance. All repairs should use genuine manufacturer parts and be carried out by experienced fitters.
WHAT INSPECTORS CHECK — THE FULL LIST
THE MOST COMMON REASONS FOR FAILURE
Based on our inspectors' experience, these are the issues we encounter most frequently:
- Missing or damaged beam safety clips — a simple fix that is often overlooked
- Bent uprights from forklift impact — even minor bends can reduce load capacity by 50% or more
- Missing load notices — every racking run must display its maximum load configuration
- No PRRS appointed — many businesses are unaware of this EN 15635 requirement
- No documented inspection history — weekly checks must be recorded, even when no damage is found
- Unauthorised modifications — extra beams added without recalculating load capacities
AFTER THE INSPECTION — WHAT HAPPENS NEXT
Your inspector will provide a detailed written report classifying all findings using the green/amber/red system. The report includes photographs, specific locations, and prioritised recommendations.
With UM Storage Systems, we don't just inspect — we fix. Our teams can often begin repairs immediately after the inspection, addressing red-risk items on the same day and scheduling amber items for prompt follow-up.
FREQUENTLY ASKED QUESTIONS
What is checked during a pallet racking inspection?
A thorough inspection covers upright frames (plumb, twist, dents), beams (deflection, connector damage), base plates and floor fixings, beam locks/safety clips, load notices, floor condition, and overall structural integrity.
How do I prepare my warehouse for a racking inspection?
Ensure all aisles are accessible, remove obstructions around racking, have previous inspection reports available, ensure load notices are displayed, and brief your PRRS on any known damage or concerns.
How long does a racking inspection take?
This depends on the size of your installation. A typical inspection of 100–200 bays takes 4–6 hours. Larger facilities may require a full day or multiple visits. UM Storage Systems provides a time estimate when booking.
What qualifications should a racking inspector have?
Inspectors should be trained to SEMA standards, have demonstrable experience in racking inspection, and understand EN 15635, EN 15512, and current HSE guidance. UM Storage Systems inspectors meet all these criteria.
What happens after the inspection?
You receive a detailed written report with photographs, damage classifications (green/amber/red), and prioritised recommendations. UM Storage Systems can carry out any required repairs, often starting immediately after the inspection.
BOOK YOUR RACKING INSPECTION TODAY
Professional, certified racking inspections from UM Storage Systems. Fast turnaround, detailed reports, and repair services available across the UK.