Why Racking Safety Matters
Warehouse racking failures can cause catastrophic injuries, product damage, and operational downtime. Regular safety inspections are not just best practice - they are often legally required under standards like EN 15635 and local workplace safety regulations.
The 15-Point Safety Checklist
Structural Integrity
- Upright Plumbness: Check that all uprights are vertical within tolerance (H/500 or as specified by the racking standard). Use a plumb line or laser level.
- Beam Connections: Verify all beam connectors are fully engaged and safety clips are in place. A dislodged beam connector is the most common cause of racking failure.
- Base Plate Condition: Ensure base plates are flat on the floor, properly anchored, and free of corrosion or damage.
- Bracing Integrity: Inspect diagonal and horizontal bracing for damage, loosening, or missing bolts.
Load Compliance
- Load Capacity Labels: Confirm that every bay has clearly visible load capacity labels showing maximum beam capacity and total bay capacity.
- Overloading: Check for visible beam deflection, bowing, or signs of stress that may indicate overloading.
- Pallet Condition: Inspect pallets for damage. Broken or non-standard pallets can cause uneven loading and local beam failure.
- Load Placement: Verify pallets are centered on beams with adequate overhang (typically 50mm on each side).
Physical Protection
- Column Protectors: Ensure all end-of-aisle uprights have column protectors installed and in good condition.
- Aisle Clearances: Maintain minimum aisle widths for the forklift type in use. Narrow aisles increase collision risk.
- Floor Condition: Check for cracks, uneven surfaces, or debris that could affect forklift stability or rack leveling.
Operational Safety
- Forklift Damage: Inspect uprights and beams for impact damage (dents, bends, scratches). Document all damage with photos.
- Lighting: Ensure all rack areas have adequate lighting (minimum 150 lux at floor level for standard operations).
- Safety Signage: Verify warning signs, load capacity notices, and operational instructions are displayed and legible.
Documentation
- Inspection Records: Maintain a log of all inspections with dates, findings, and corrective actions. This is a legal requirement under EN 15635 in the EU.
Inspection Frequency
- Daily visual checks: Performed by warehouse staff
- Weekly formal inspection: Supervised walk-through
- Monthly detailed inspection: Documented assessment of all items above
- Annual expert inspection: By a qualified racking inspector (required by EN 15635)