Racking Safety Best Practices for UK Distribution Centres

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Distribution centres across the UK are under constant pressure — fast deliveries, high stock turnover, and the need for maximum efficiency. In such demanding environments, pallet racking systems play a crucial role. But without proper safety measures, these same systems can become a major source of risk.

The Health and Safety Executive (HSE) and the Storage Equipment Manufacturers Association (SEMA) set clear expectations for warehouse and racking safety. By following their guidance, UK distribution centres can prevent accidents, protect employees, and avoid costly downtime.

Here are the essential racking safety best practices every UK distribution centre should follow.

1. Carry Out Regular Racking Inspections

  • Weekly Checks: Conducted by the Person Responsible for Racking Safety (PRRS), these inspections catch early signs of damage such as bent uprights, missing beam locks, or impact marks from forklifts.

  • Annual Inspections: Required under HSE HSG76 guidance, annual inspections should be carried out by a SEMA Approved Racking Inspector (SARI). This ensures a detailed assessment and a written risk-based report.

👉 Inspections not only maintain compliance but also prevent accidents before they happen.

2. Train Warehouse Staff on Racking Safety

Employee awareness is critical. All staff should be trained to:

  • Recognise damage indicators (e.g., leaning racks, twisted frames).

  • Report issues immediately to the PRRS.

  • Follow correct pallet placement and loading techniques.

Training reduces the risk of unsafe practices and reinforces a culture of safety.

3. Prevent Forklift-Related Damage

Forklifts are one of the leading causes of racking accidents in UK warehouses. Best practices include:

  • Installing rack protection guards at aisle ends.

  • Marking clear travel routes with floor lines.

  • Providing forklift operator refresher training.

  • Limiting speed in high-traffic zones.

4. Follow Load Limits and Manufacturer Guidance

Overloading racks is a serious safety hazard. Distribution centres should:

  • Clearly display safe working load signs on all racking.

  • Ensure pallets are stacked evenly and correctly.

  • Never mix incompatible pallet types on the same rack.

5. Keep Records and Take Immediate Action

  • Use a damage logbook to track inspection results.

  • Take immediate corrective action on red risk areas (as per SEMA traffic light system).

  • Keep repair records for insurance and compliance purposes.

6. Maintain Good Warehouse Housekeeping

  • Keep aisles free of obstructions.

  • Ensure adequate lighting for visibility.

  • Remove damaged pallets from circulation.

Simple housekeeping habits drastically reduce the risk of racking damage.

Final Thoughts

UK distribution centres are the backbone of retail and logistics, but without strong safety measures, racking systems can quickly become a liability. By combining weekly internal checks, annual expert inspections, and strict adherence to HSE and SEMA guidance, warehouses can ensure both safety and efficiency.

Safe racking doesn’t just protect stock — it protects people, reduces downtime, and safeguards business reputation.

📌 Learn more about professional racking inspections across the UK at seerackinginspections.co.uk

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