Solving Warehouse Storage Challenges with Pallet Racking
Pallet racking is the steel shelving framework that stores palletised goods in rows and levels, so warehouses can use their full height and pick stock quickly by forklift. Choosing the right type, and keeping it inspected and repaired, is what keeps it safe and productive.
This guide covers the main types of pallet racking, how racking inspections work under UK guidance, what the red, amber and green damage ratings mean, and when racking should be repaired.
What Is Pallet Racking?
Pallet racking is made of upright frames joined by horizontal beams. Pallets sit on the beams, either directly or on mesh decking. Because the beam levels can be adjusted, the same racking can be reconfigured as your stock changes.
Racking works alongside the containers you store on it. Pallet cages and magnum containers built to a standard pallet footprint can be stored on racking just like a pallet, as long as the beam load rating allows it.
Types of Pallet Racking
| Racking type | How it works | Best for |
|---|---|---|
| Adjustable (selective) pallet racking | Single rows with direct access to every pallet | Mixed stock and frequent picking |
| Narrow aisle racking | Selective racking with narrower aisles, served by specialist trucks | Getting more storage into the same floor space |
| Drive-in / drive-through racking | Forklifts drive into the racking lanes | High volumes of the same product |
| Push-back racking | Pallets sit on carts that roll back on inclined rails | Dense storage with better access than drive-in |
| Pallet live (flow) racking | Pallets roll forward on gravity rollers | First-in, first-out stock such as food |
| Cantilever racking | Arms extend from a central column, with no front uprights | Long items such as timber, pipes and steel |
Adjustable pallet racking is the most common type in UK warehouses because every pallet is accessible. Denser systems store more but give up some access. To see how racking choices affect capacity, read increase capacity and productivity with your warehouse racking system.
Pallet Racking Safety and the Law
Damaged racking can collapse, and one failure can bring down neighbouring bays. In the UK, the HSE’s warehousing guidance (HSG76) says racking should be inspected by a technically competent person at intervals of no more than 12 months. Industry practice, set by SEMA (the Storage Equipment Manufacturers’ Association), adds regular in-house checks between those expert inspections.
A good racking safety routine includes:
- A named person responsible for racking safety, who carries out and records regular visual checks
- Weekly visual inspections by trained staff, looking for impact damage, missing parts and overloading
- An expert inspection at least once a year by a qualified racking inspector, with a written report
- Clear load notices on every run, showing the safe working load per beam level and per bay
- Rack protectors on uprights and end frames in busy aisles
See our health and safety approach and our tips on how to keep your warehouse safe.
Racking Damage Ratings: Red, Amber and Green
Racking inspections grade each defect using SEMA’s traffic light system, so you know exactly how urgently it needs fixing.
| Rating | What it means | Action |
|---|---|---|
| Red | Serious damage beyond the safe limit | Offload the area immediately and isolate it until it is repaired |
| Amber | Damage that needs repair but is not yet critical | Repair as soon as possible; offload within four weeks if not fixed, and do not reload until repaired |
| Green | Damage within acceptable limits | Keep using the racking; record it and monitor at the next inspection |
The most common causes of damage are forklift impacts on uprights, beams knocked out of place, missing safety locks, and loads heavier than the rating.
Pallet Racking Repairs
Most racking damage can be repaired by replacing the affected components, such as a bent upright, beam or bracing, rather than replacing the whole run. Repairs should always use compatible components and be carried out by trained engineers, because mixing incompatible parts can reduce the racking’s safe load.
Our trained engineers inspect, repair and install warehouse racking to SEIRS standards, following HSG76 and the SEMA code of practice. We supply both new and refurbished racking systems, and offer full installation and dismantling. Our mobile engineers cover sites across the UK.
Protecting Your Racking
Prevention is cheaper than repair. Fitting rack guard protectors is one of the cheapest ways to reduce the risk of accidents. We supply narrow aisle protectors, corner guard protectors and standard guard protectors in new and refurbished metal.
Other simple steps help too: keep aisles clear, train forklift drivers on racking awareness, never exceed the load notice, and report every impact, however small. For smaller items that do not need pallet racking, consider industrial shelving.
FAQ
What is pallet racking?
Pallet racking is a steel storage system of upright frames and horizontal beams that holds palletised goods at several levels, so warehouses can use their full height.
What are the main types of pallet racking?
The main types are adjustable (selective) pallet racking, narrow aisle, drive-in and drive-through, push-back, pallet live (flow) and cantilever racking.
How often should pallet racking be inspected?
UK HSE guidance (HSG76) says a technically competent person should inspect racking at intervals of no more than 12 months. Trained staff should also carry out regular visual checks, usually weekly.
What do red, amber and green mean on a racking inspection?
Red means serious damage: offload and isolate immediately. Amber means repair is needed: offload within four weeks if it is not fixed. Green means the damage is within acceptable limits and should be monitored.
Can damaged pallet racking be repaired?
Yes. Damaged uprights, beams and bracing can usually be replaced with compatible components by trained engineers, without replacing the whole run.
Do you supply and install pallet racking?
Yes. We supply new and refurbished racking systems, and our engineers inspect, repair, install and dismantle warehouse racking to SEIRS standards.
Keep Your Racking Safe and Productive
The right pallet racking helps you store more and pick faster, but only if it is inspected and repaired properly. Distribution Maintenance inspects, repairs and installs warehouse racking across the UK from our depots in Harlow and Grantham.
Request a quote or contact our team to book a racking inspection or repair.
