How often should racking be inspected, and after an impact?

Why do racking inspections matter?

A racking system carries tonnes of goods, and daily operation gradually wears it down: forklift impacts, overloading and moving beams without a plan. A damaged upright or beam often looks harmless, yet it can significantly reduce load capacity. Regular inspection catches problems before they become dangerous.

Who is responsible for racking safety?

The European standard EN 15635 places responsibility for safe use of racking on the user. In practice the company appoints a person responsible for storage equipment safety (PRSES in the standard), who organises inspections, keeps records and decides what to do after damage.

How often should racking be inspected?

In warehouses with heavy forklift traffic, or after changes to the system, inspections are carried out more often.

What do green, amber and red mean?

Under EN 15635, damage is classified into three risk levels:

• Green – damage is within acceptable limits. The component is recorded and monitored at the next inspections.
• Amber – damage needs repair soon. No new goods are placed on the affected locations until the component is replaced.
• Red – serious damage. The bay is unloaded and isolated immediately, and the component replaced before reuse.

What should you do after a forklift impact?

1. Stop work in that area and report the impact to the person responsible for racking safety.
2. If damage is visible, carefully unload the affected bay and any adjacent bays sharing the same upright.
3. Isolate the bay, for example with tape or signage, so nobody puts new goods on it.
4. Have a competent person assess the damage and assign the risk category.
5. Replace damaged components with original parts from the same manufacturer and with the same capacity.

What must you never do?

• Do not straighten bent uprights or beams. Straightened steel does not have the same capacity.
• Do not weld or drill racking components on site.
• Do not change beam levels without checking capacities and updating load notices.
• Do not fit components from other manufacturers without checking compatibility.

How can damage be reduced?

• Upright protectors where forklifts pass most often
• End-of-aisle and corner upright protection
• Clear load notices on every rack
• Aisles wide enough for the equipment you use
• Forklift driver training and clear traffic rules in the warehouse

How does EL-FAM help?

EL-FAM inspects racking systems, prepares a report with priorities and replaces damaged components. Because we manufacture our racking ourselves, replacement parts and upright protection are available quickly, and after assessment we also work on systems we did not install. Send us basic details about your warehouse and racking, and we will arrange an inspection.