Why does racking need maintenance?
A racking system is an investment meant to last for years. Yet daily operation gradually reduces its safety: forklift impacts, overloaded levels and beams moved without checking capacity. A dented upright or a bent beam often looks harmless, but even minor deformation can significantly reduce the capacity of the whole bay.
Maintenance is therefore about more than appearance. It protects the people working in the aisles, the goods on the racks and the value of the system itself.
Who should inspect racking, and how often?
EN 15635, the standard covering the use and maintenance of storage racking, provides for several levels of checks:
- Immediately after an impact – drivers and staff report every impact or visible damage.
- Regular visual inspections – the person responsible for racking safety checks the system at regular intervals, typically weekly or monthly depending on how busy the warehouse is.
- Expert inspection – a technically competent person inspects the entire system at least every 12 months and provides a written report.
What is checked during an inspection?
- frame uprights: dents, bends, cracked welds
- frame bracing (diagonals and horizontals)
- beams: deflection, deformation, beam locks in place
- anchors and shims at the floor
- frame verticality
- decking, pallet stops and anti-collapse mesh
- load notices: present and matching the actual configuration
How is damage classified?
EN 15635 uses a simple three-colour system that makes it clear straight away what is urgent:
| Level | Meaning | Action |
|---|---|---|
| Green | Damage within acceptable limits | Record it and monitor at the next inspection |
| Amber | Damage that needs repair | Do not reload once emptied; replace the component soon |
| Red | Serious damage | Unload immediately and isolate that part of the system until repaired |
How can you reduce damage?
Prevention always costs less than repair. The most effective measures are:
- upright and end-of-aisle protection, especially at corners and main traffic routes
- aisles wide enough for the forklifts actually in use
- clear, visible load notices
- forklift driver training and a clear rule to report every impact
- changing beam positions only after checking load capacity
What if a rack is damaged?
A damaged component is not straightened or welded on site; it is replaced with a new one of the same dimensions and capacity. During replacement that part of the system is unloaded and closed off. That is why quick access to replacement parts matters.
How does EL-FAM help with maintenance?
EL-FAM inspects racking systems, provides a report on their condition with priorities, and replaces damaged components. Because we manufacture our own racking, we produce replacement parts to the dimensions required. Get in touch with basic details about your system and we will arrange an inspection.
Frequently asked questions
How often should racking be inspected?
Under EN 15635, the user carries out regular visual checks and a technically competent person carries out an expert inspection at least every 12 months. Every impact should be reported immediately.
Can a damaged upright be straightened or welded?
No. The damaged component is replaced with a new one of the same dimensions and capacity, and that part of the system is unloaded and closed off until then.
What does red damage mean?
Red means serious damage. That part of the racking must be unloaded immediately and isolated until the component is replaced.
Can you inspect racking installed by another company?
Yes. The inspection follows the same process, and for replacement parts the dimensions and capacity of the existing components need to be established.
