SEMA Approved Racking Inspector Checklist: Ensure Your Racking Meets UK Standards

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Pallet racking systems are the backbone of any warehouse, but even the strongest structures can become unsafe without regular inspections and maintenance. In the UK, the Health and Safety Executive (HSE) recommends that all racking undergo an annual expert inspection by a SEMA Approved Racking Inspector (SARI).

To help you stay compliant and prepare for professional inspections, we’ve put together a comprehensive SEMA inspection checklist. This will give your team a clear understanding of what inspectors look for and ensure your racking meets SEMA and HSE UK safety standards.

1. Uprights and Frames

A key focus during inspections is the condition and stability of uprights and frames. SARIs check for:

  • Bent, twisted, or damaged uprights
  • Signs of impact damage from forklifts or pallet trucks
  • Loose or missing base plates and fixings
  • Corrosion or rust that may weaken the structure
  • Proper installation and alignment of all frames

Even minor damage can significantly reduce load capacity, so issues here are flagged as high priority.

2. Beams and Beam Connectors

Beams support the entire weight of stored goods. Inspectors check for:

  • Bending or deflection beyond manufacturer limits
  • Cracked welds or damaged end connectors
  • Missing locking pins or safety clips
  • Overloaded beams or beams used outside their intended design

These checks help ensure beams remain stable and won’t fail under load.

3. Bracing and Stability Components

The bracing structure ensures your racking remains rigid and stable. SEMA inspectors assess:

  • Damaged or missing horizontal and diagonal bracing
  • Misaligned or loose fixings
  • Evidence of previous repairs not carried out to standard

A compromised bracing system can make the entire structure unstable.

4. Floor Fixings and Base Plates

To comply with UK standards, racks must be securely anchored to the floor. The checklist includes:

  • Presence and condition of base plates
  • Secure floor bolts with no movement
  • Correct alignment of racking to prevent uneven loads

Loose or missing fixings are flagged for immediate repair.

5. Load Notices and Signage

Clear and accurate load notices are essential for safety and compliance. Inspectors verify that:

  • Load notices are visible and securely fixed
  • Information includes maximum bay load, maximum beam load, and manufacturer details
  • Load signs reflect the actual configuration in use

Missing or outdated signs can lead to unsafe loading practices.

6. Rack Protection and Safety Accessories

Preventative protection plays a big role in reducing impact damage. The checklist covers:

  • Rack guards and column protectors installed at high-traffic areas
  • Barriers or bollards protecting end frames
  • Safety locks and beam pins correctly fitted
  • Pallet backstops or anti-collapse mesh (where applicable)

These accessories are often overlooked but make a big difference in accident prevention.

7. Housekeeping and Aisle Conditions

A safe racking system also depends on good housekeeping. SARI inspectors check:

  • Clear and unobstructed aisles
  • No pallet overhang or unsafe stacking
  • Adequate lighting for inspection and daily use
  • Access for emergency exits and fire safety compliance

Good housekeeping ensures safe operation between inspections.

8. Documentation and Inspection Records

Finally, inspectors review your inspection history and maintenance records to ensure:

  • Regular in-house visual inspections are being carried out (usually weekly)
  • Previous SEMA inspection reports are filed and acted upon
  • Repairs have been completed to the required standard
  • An action log is maintained for any identified issues

Proper documentation proves compliance during audits and protects your business legally.

Why Use This Checklist

Using a SEMA-approved checklist throughout the year allows you to:

  • Identify and fix minor issues before they become serious
  • Prepare for your annual expert inspection with no surprises
  • Keep your team safe and your warehouse compliant
  • Extend the lifespan of your racking systems

Conclusion

A SEMA Approved Racking Inspector checklist is more than a safety tool it’s your roadmap to compliance with UK warehouse safety standards. Regular internal checks, combined with an annual SARI inspection, keep your warehouse running safely, efficiently, and legally.

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