It started with a single missing safety clip. No one noticed… until the racking collapsed. Stock was destroyed, operations were halted, and the fine from HSE? Even worse. Sadly, this scenario isn’t rare. Under PUWER (Provision and Use of Work Equipment Regulations), by law, pallet racking is classified as work equipment. It must therefore be inspected and maintained regularly to meet UK health and safety laws. However, many businesses aren’t clear on how often these checks should happen or what they must include.
This guide is here to help. We’ve created a step-by-step PUWER inspection checklist specifically for pallet racking systems. It touches on daily checks, expert inspections, and legal requirements. If you’re new to compliance or checking your process, this checklist should be a nice introduction. Although please note, it is by no means exhaustive!
Keep reading to protect your staff, stock, and business before problems happen.
Why PUWER Inspections are Crucial for Pallet Racking Safety
Pallet racking systems are the backbone of warehouse operations, but if neglected, they can quickly become a safety hazard. Regular PUWER inspections aren’t just about ticking boxes. They work to prevent accidents, prolong the life of your racking systems, and ensure compliance with UK safety standards.
Under PUWER, all work equipment, including pallet racking, must be appropriately maintained. The Health and Safety Executive (HSE) mandates regular inspections. This act helps ensure safety in your workplace and enables you to avoid legal repercussions. A system that fails an inspection can lead to fines, stock loss, and even work stoppages.
So, what happens when you stay on top of your racking system’s inspection and maintenance? It’s simple: you proactively protect your team, invest in your inventory, and overall business operations. Why? Because regular inspections can catch minor issues before they snowball into costly problems.
Key Steps in a PUWER Pallet Racking Inspection
Ensuring your racking system is safe and compliant doesn’t have to be complicated. Following a structured inspection process is the key to keeping your warehouse running smoothly and safely.
Here’s a breakdown of the essential steps:
1. Daily Visual Checks
Before each shift, your warehouse team should conduct quick visual checks to identify any obvious issues. This doesn’t replace in-depth inspections, but is an essential first line of defence.
Key things to look for include:
- Bent uprights: Even minor bends can weaken the entire racking system.
- Misaligned beams: Misalignment can lead to uneven loads, increasing collapse risk.
- Missing safety pins, clips, or bolts: These components keep the system secure.
- Load distribution: Ensure pallets are evenly distributed to avoid tipping.
Daily checks help you catch potential issues early. This allows your team to report concerns before they become bigger problems.
2. Regular Maintenance & Repairs
Under PUWER regulations, pallet racking systems must undergo regular maintenance. This helps them to remain safe and compliant. However, the maintenance frequency varies depending on your racking system’s use.
For example:
- High-traffic warehouses: Monthly maintenance ensures the system remains stable under constant use.
- Medium-traffic areas: Inspections should take place every three to six months.
- Low-traffic areas: These can be checked annually.
Maintenance tasks should include tightening bolts, repairing bent beams, and stabilising floor fixings. The goal is to reduce wear and tear before it leads to downtime or accidents.
3. Annual Expert Inspections
PUWER mandates that qualified experts conduct annual inspections in addition to daily checks and regular maintenance. According to the Health and Safety Executive (HSE), a SEMA-approved racking inspector (SARI) should perform these inspections.
A SARI inspection goes beyond daily or monthly checks and delves into the structural integrity of the racking system.
These inspections typically cover:
- Structural integrity: Assessing beams, uprights, and bracing for damage.
- Impact damage: Checking for any evidence of forklift collisions.
- Load compliance: Verifying that weight limits are respected.
- Safety accessories: Ensuring components like beam locks and rack protectors are intact.
After the annual inspection, you’ll receive a detailed report that outlines the condition of your racks and any actions you should take.
What to Do if You Spot Damage
- Isolate the damaged area: Prevent further use to avoid accidents.
- Label the area: Make it clear to others that the racking is unsafe.
- Contact a specialist: Contact a qualified expert to assess and repair the damage.
- Document the issue: Keep a detailed record for compliance and safety audits.
If you need it, First Floors provides emergency racking repairs. Our team also does this with minimal disruption, so your warehouse remains safe and compliant.
Protect Your Warehouse the Smart Way
PUWER inspections for pallet racking are a proactive way of keeping your people, products, and business safe. Catching potential issues early not only lowers the risk of accidents and costly downtime. It also extends the life of your racking systems and keeps your warehouse operations running smoothly.
If your warehouse often faces overloading, messy storage, or struggles to meet growing demand, it might be time for a bigger solution. An inspection might reveal more than just wear and tear. It could indicate that your layout is no longer optimised for your needs. This is where a bespoke mezzanine floor can help. It’s a cost-effective way to boost usable space and reduce pressure on your racking system. Plus, it avoids the hassle and expense of relocating your business!
At First Floors, we’ll ensure your racking systems meet compliance and help your warehouse operate safely and efficiently. We provide thorough PUWER-compliant racking inspections and tailor-made mezzanine floor installations. Regardless of your facility’s size, we’re ready to support your growth.
Call 01789 764172 or schedule your pallet racking inspection with First Floors today and expand your warehouse space.