Rack Repairs Checklist

In the dynamic landscape of warehouse management, maintaining the integrity of storage systems is paramount to ensuring both worker safety and operational efficiency. Racking systems, the backbone of any warehouse, play a crucial role in storing and organising inventory. However, wear and tear over time or unexpected incidents can compromise the structural integrity of these racks, posing potential risks.

To address these concerns and proactively enhance warehouse safety, a meticulous racking repair checklist becomes indispensable. This article introduces you to the key elements of a comprehensive racking repair checklist, guiding warehouse managers and operators through the essential steps to assess, address, and fortify their storage infrastructure. By prioritising regular inspections and timely repairs, businesses can not only adhere to safety standards but also optimise their overall warehouse performance.


Rack Repair Checklist.

1. Visual Inspection:

Check for bent, damaged, or twisted components.

Look for any signs of rust or corrosion.

Inspect the overall condition of the racking structure.

2. Beam Levels:

Ensure beams are level and not sagging.

Check for any visible cracks or damage on the beams.

Verify that beams are properly seated in the connectors.

3. Uprights:

Examine uprights for any dents, bends, or deformation.

Check the anchoring of uprights to the floor.

Inspect for signs of rust or corrosion on uprights.

4. Bracing:

Confirm that diagonal braces are in place and secured.

Inspect horizontal braces for any damage or disconnection.

Ensure that all bracing components are properly connected.

5. Wire Decking:

Inspect wire decking for any broken or damaged wires.

Check the integrity of the wire mesh.

Confirm that wire decking is properly seated on beams.

6. Load Capacities:

Verify that the racking is not overloaded.

Check load labels to ensure compliance with weight limits.

Ensure that heavier items are stored on lower levels.

7. Safety Clips/Pins:

Confirm that safety clips or pins are securely in place.

Inspect for any missing or damaged safety components.

8. Floor Conditions:

Check the floor for any unevenness or damage around the racking.

Verify that the racking is securely anchored to the floor.

9. Clear Aisles:

Ensure that aisles are clear of obstructions.

Check for any items that may have fallen and could impact the racking.

10. Documentation:

Review maintenance and inspection records.

Verify that any identified issues from previous inspections have been addressed.

11. Emergency Procedures:

Ensure that emergency procedures for racking failures are clearly documented.

Confirm that employees are trained on emergency evacuation plans.

12. Professional Inspection:

Schedule regular professional inspections by qualified personnel.

Follow up on any recommendations made by inspectors.

13. Training:

Ensure that warehouse staff are trained to recognize and report potential issues.

Conduct regular training sessions on safe loading and unloading practices.

14. Repairs and Maintenance:

Promptly address any issues identified during inspections.

Document repairs and maintenance activities.

15. Communication:

Establish clear communication channels for reporting racking concerns.

Encourage a culture of safety awareness among warehouse staff.


Regular inspections and proactive maintenance are essential for ensuring the safety and structural integrity of warehouse racking systems. Always follow manufacturer guidelines and industry standards when conducting inspections and making repairs.


What To Look For.

  1. Any changes that significantly change the shape of the structural component eg. dents, buckles, tears, or splits.
  2. Any damage that weakens a jointed member, such as weld cracking.
  3. Pallets used within the racking system must be suitable, in good condition and correctly stacked.
  4. Vertically issues with the uprights caused by impact damage or poor loading practices.
  5. The misalignment of bays caused by impact or movement from fork lift trucks for example.
  6. The incorrect location of beam connectors. They must be installed level.
  7. Missing beam connector locks. SEMA and HSE insist that beam locking clips are installed to any racking system that is loaded by MHE to prevent dislodgement of a beam. Spares should be kept on site.
  8. Incorrectly bolted or screwed beams.
  9. Loose or missing floor fixings. 1x suitable floor fixing per footplate should be installed to any racking system that operate in an area where MHE operate.
  10. Damaged missing or incorrect baseplates. Baseplates should be: fitted to every upright, in good condition, securely attached, fully supporting the upright profile.
  11. Shim plates should fit under the entire baseplate profile.
  12. Missing or damaged bracing.
  13. The dislodgement of accessories. These could fall and present a risk of injury to pedestrians and vehicle traffic.
  14. The spillage of goods presents the same risk as above.
  15. Missing or incorrectly located row spacers. The SEMA code of practice requires that run spacers are to be fitted at the first bracing node point on the frame, at the top bracing node and then no more than 3.6m intervals and also fitted within 225mm of a node point.
  16. Beam and connectors, which show any clearly visible signs of deformation. This includes damage to the hooks or lugs on the rear of the beam connectors.


Always follow manufacturer guidelines and industry standards when conducting inspections and making repairs on your racking.


Contact NSI Projects at 0800 027 1966

Or email: sales@nsiprojects.co.uk

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