Avoid These Common Mistakes Found During Racking Inspections

Proper racking inspection is essential to maintaining a safe and efficient warehouse. Racking systems carry heavy loads and are frequently exposed to wear and tear. Without regular checks, minor issues can escalate into serious hazards—causing damage to goods, injuries to staff, or even full system collapse. Unfortunately, many businesses unknowingly make critical errors during racking inspections. In this blog, we’ll cover the most common mistakes and how you can avoid them to ensure safety and compliance. 

1. Skipping Scheduled Inspections

One of the biggest mistakes is failing to conduct racking inspections at regular intervals. Many warehouses only check their racks when there's a visible problem or after an incident occurs. However, racking damage often starts small and goes unnoticed until it's too late. To stay compliant with safety standards (such as SEMA in the UK), inspections should be done on a weekly basis by in-house staff and at least once a year by a qualified expert. A missed inspection could result in liability if an accident occurs.

2. Using Untrained Personnel for Inspections

Another common oversight is assigning inspections to untrained or inexperienced staff. Racking inspection is not just a box-ticking exercise—it requires knowledge of the racking system’s design, loading limits, and potential failure points. Only trained personnel can accurately identify warning signs like misaligned frames, bent uprights, or missing safety pins. Investing in proper training or using certified racking inspectors can save thousands in damage repairs and legal fees.

3. Ignoring Minor Damage

Small dents, paint scrapes, or slightly twisted beams might seem harmless, but they often indicate a deeper structural issue. Over time, these "minor" problems can compromise the entire racking system’s integrity. For instance, even a 3 mm deflection in a beam could exceed safe limits. It’s important to treat every sign of damage seriously and take corrective action immediately, rather than waiting until the problem becomes severe.

4. Overloading the Racks

Many warehouse accidents are caused by overloading racking systems beyond their rated capacity. This happens when labels indicating weight limits are missing, unclear, or ignored. Forklift operators and warehouse staff may not realize they’re stacking pallets too high or placing heavier items on upper levels. Always ensure that load capacity labels are clearly displayed and staff are aware of the weight limits.

5. Poor Record Keeping

Even if inspections are carried out regularly, failing to keep proper documentation is a mistake. Inspection records are crucial for proving compliance with health and safety regulations. They also serve as a reference for tracking recurring issues or identifying patterns in damage. A good inspection log should include the date, inspector’s name, identified issues, and corrective actions taken.

6. Performing Unauthorised Repairs

When damage is found, it’s tempting to fix the issue quickly using in-house maintenance teams. However, unauthorised or DIY repairs can be extremely dangerous. Racking components should only be repaired or replaced according to the manufacturer’s guidelines and preferably under the supervision of a qualified racking engineer. Improper welding, the use of non-compatible parts, or simply bolting things back together can lead to system failure under load.

7. Clutter and Poor Housekeeping

Inspections become difficult and less effective when the base of racking systems is blocked by boxes, pallets, or debris. Good housekeeping is essential for a clear line of sight during inspections. Clean, clutter-free aisles not only make it easier to spot damage but also reduce trip hazards and improve forklift access. Encourage a clean-as-you-go policy to maintain a safe inspection environment.

Conclusion

Racking inspections are a vital part of warehouse safety, but their effectiveness depends on doing them right. By avoiding the common mistakes listed above—like skipping inspections, using untrained staff, or overlooking small issues—you can protect your workers, prevent costly damage, and stay compliant with safety regulations.

To help you get started, we’ve created a free downloadable Racking Inspection Checklist you can use during your next inspection. Or, if you'd prefer a professional touch, book an expert racking inspection with our certified team today.