The 5 Steps You Need for Warehouse Racking Safety
The 5 Steps You Need for Warehouse Racking Safety
Employee safety in the workplace is a non-negotiable requirement. Every day, your employees arrive at work and expect to go home safely at the end of each shift. This should come as a standard regardless of your industry, whether in an office, on a farm or in a warehouse. Yet look at Health & Safety figures and you soon discover that some industries, such as manufacturing and logistics, remain the most dangerous places to work. A position that year-on-year remains in the top 5 list!
So, what’s causing the problem in these industries? Why is logistics and the warehousing industry suffering? After all, there is plenty of information, guidance and safety measures available that will steer owners and managers of warehouses in the right direction.
Safety risks in the warehouse
The issues are multi-faceted. The presence of automated systems within the warehouse has grown significantly but with it comes an increase in orders and extra considerations which need building into the layout of the space. Warehouses have also developed to become busier than ever. Not only through order processing and movement of stock, but also as multi-functional spaces with the need to handle orders and additional tasks such as returns, recycling and stock management. Layer this with the e-commerce boom making warehouses busier than ever and it’s not hard why problems build.
The second issue is the backbone of your warehouse – your racking. That important equipment fills a large area in the warehouse and is possibly one of the hardest working members of your team. The racking has to hold heavy weights of stock securely above employees’ heads while also creating a safe working environment on the warehouse floor and making stock accessible. Yet some managers or those persons responsible for health and safety in the warehouse are still wholly unaware of the fragile line between a safe storage rack and the potential for a serious accident.
Pallet racking systems role in the warehouse
Making racking safe is a fairly simple process but far too many rely on the supplier to do the job and ‘get it right’. In reality, it is the responsibility of the warehouse owner or manager to ensure the correct regulations and industry pallet rack safety guidelines are followed. It’s a simple process but it does require for each safety step to be followed to be effective.
That’s why in 2025, SEMA wants to shout out loud about how adopting five simple steps can enhance the warehouse and create a safe environment for employees.
Step 1: The right racking design for the task
In most cases, an empty warehouse is a large box that needs filling. A space ready to be enhanced with clever racking design that maximises efficiencies, optimises storage capacity and increases productivity. Most racking designs should be able to meet these requirements. However, in today’s modern warehouse your racking has to perform to a much higher level.
First, you now need a warehouse that can cover multiple tasks. Whether that’s handling online orders, holding stock for high street shops, dealing with returns or incorporating recycling initiatives. Racking also needs to seamlessly blend with new technology such as automation and WMS systems while also factoring protection measures that enhance safety for warehouse employees. On top of this, the dynamics of a warehouses has now changed, and they can range anywhere from a micro hub for last-mile delivery to a big shed with racking systems that easily reach 20m in height. Each one has its own racking requirements which require a different approach.
Meeting this list is no easy task. It requires precise engineering and design combined with the correct type of racking for the task to ensure maximum productivity, safety and profitability.
Step 2: Choose your supplier carefully
This complexity of warehouse spaces in this day and age requires a supplier and design team who have the skills to navigate the changing footprint of a warehouse with in-depth knowledge of the industry.
Gone are the days when warehouse owners can leave the purchase of their equipment to chance but, in a crowded racking supplier market, it can be hard to know which racking company to trust. The problem of which company to work with becomes even more complicated when you consider that a racking structure may look impressive on a webpage but that doesn’t guarantee it can meet expected proper loading and carrying capacity, correct fixings, manufacturing quality or a safe design. Choose an inexperienced supplier who doesn’t understand the complexities of storage equipment and how to meet industry regulations and it quickly reduces the cost effectiveness of the rack system you have purchased.
Who are SEMA
Rack manufacturer and supplier companies in the UK and across the globe formed SEMA to provide clarity to the industry. These companies commit to meeting high safety and quality standards. A member can only join SEMA as an approved member once they have passed a Membership Standard Assessment. The audit process is in-depth and covers five key areas by ensuring they work to relevant codes of practice and meet SEMA and industry standards. It also checks they conform to health and safety requirements while also reducing their environmental impact. Plus, to save the leg work for the client, the audit checks they have the correct legal and insurance documentation in place.
Step 3: Signage
Safety signs are a key tool in UK warehouses. They act as visual cues that remind employees about the essential information that will keep them safe. The aim of the signs is to communicate in a clear and simply way the potential hazards that are around them in the warehouse. There are lots of different signs that cover safe behaviour in the warehouse, correct use of PPE and prohibiting actions that could lead to accidents and safety instructions.
Signs also apply to your racking structure. Load Notices are important signs that inform anyone working in areas with racking about the type and weight of stock the structure can hold. It may not seem an important part of the racking but it plays a vital role. Pallets with heavy loads on the racking can easily weigh up to 1.5 tonne (the same as a small car). If they suddenly fall, for example if racking is unable to hold the weight due to incorrect loading, the consequences can be devastating. The pallet will take only seconds to reach the floor from a height of 10 metres and by that point it will be travelling at around 30mph when it finally hits.
SEMA Standards for Racking Safety
When SEMA members supply their equipment, they design the racking or shelving structure for load capacities that meet the type and weight of stock. First, your team should be given safety training on how to correctly load the racking for the specified weight. The supplier should also give you instructions on proper loading capacities for the storage equipment whether that’s in an instruction manual or an operation and maintenance manual. But, out on the warehouse floor, it’s always useful to have reminders. This is where Load Notices come into play. The notice provides general safety warnings and information about the supplier. However, it also provides specific information relevant to the installation including limitations and the number of pallets and maximum load capacity that can be placed on beams.
Step 4: Inspection, Inspection, Inspection
We cannot say it enough, to keep racking safe you MUST continuously inspect the structure. Our SEMA Approved Racking Inspectors (SARI) are constantly checking racking in warehouses and it still amazes them how many times the owner is wholly unaware of their responsibilities when maintaining the structure.
The process is simple:
Inspect every day
- Train your team so they recognise potential issues and signs of damage on racking.
- Instruct on the correct reporting process if damage is found.
Inspect regularly
- Train a member of your team to undertake the role of Person Responsible for Racking Safety (PRRS) who will conduct in-house inspections.
- The PRRS will need to conduct a visual inspection of the racking structure which will check Load Notices are fixed to the racking, maximum loads are never exceeded, correct usage and look for signs of rack damage.
- The PRRS will maintain a written record of regular inspections including the findings which report on any rack damage levels.
Inspect at least once a year
- Ask a qualified racking inspector, such as a SEMA Approved Racking Inspector (SARI), to conduct an Expert Inspection on your rack structure.
- Within the industry there are two types of a professional rack safety inspection available – a damage report or a report by a SEMA Approved Racking Inspector.
- A damage report only provides a damage list and location of damaged items. The SARI report goes into greater detail by looking at the suitability of the storage equipment and mechanical handling equipment, load stability, rack configuration and compatibility of the racking. It also provides a list of damage with timescales for corrective action.
Step 5: Training, Training, Training
Training is the cornerstone to upholding pallet rack safety standards and best practice. Within the industry, there are few courses dedicated to racking practices which is why SEMA has set up training to cover key stages in the lifetime of your storage equipment.
Racking Installer Training
Quality in the installation of your racking system is an often overlooked area and one that most warehouse owners leave the supplier to ‘sort out’. Yet, guidance by the Health & Safety Executive (HSE) requires the client ordering the racking to check the team installing the structure is qualified for the job.
To help navigate area, SEMA set up the SEIRS training scheme for installers of racking equipment. Installers who have been on SEIRS courses can prove they have undertaken training for installing pallet racking systems and meet the highest industry standards and codes of practice. The course trains racking installers on correct installation methods in accordance with SEMA standards, manufacturer specifications and codes of practice. We offer five courses for installers that build into a solid foundation that covers industry-specific issues, Health & Safety, practical instruction on installing storage equipment, and a rigorous assessment process.
Rack Safety Awareness
To prepare the PRRS for conducting regular inspections or anyone working in areas with racking we offer our Rack Safety Awareness training (RSA).
Referenced in HSG76 Warehousing and storage: A guide to health and safety, this one-day classroom-based course provides essential training, knowledge, and skills needed to carry out duties safely. It covers types and frequency of inspections, responsibilities of users and suppliers, legislation, recording an inspection, potential damage levels, understanding load notices and action points. We run two courses that cover either pallet racking and cantilever racking.
Expert Inspections
The SARI qualification is for professionals who conduct third-party rack inspections and want to uphold a high-quality standard in their work. This course is intended for candidates who can already demonstrate experience in racking inspections and are ready to take their skills to the next level.
The SARI course comprises an intensive three-day training course and successful completion of both a written examination and practical assessment. To substantiate their qualification and commitment to the industry, SARIs must also undergo Continuous Professional Development (CPD) There are currently two separate modules relating to the SEMA Approved Rack Inspector Qualification - Adjustable Pallet Racking and Cantilever Racking.
Make 2025 the year of pallet racking safety
While the list of jobs to consider when it comes to the racking can be overwhelming, SEMA are on a mission in 2025 to break it down for warehouse owners. Follow our 5 steps and collectively we can improve warehouse operations and safety.
For over 50 years, SEMA has worked hard with the help of our members and training initiatives to make the process of getting new and maintaining your racking as easy as possible. If you’re getting new racking or maybe need to improve your current system, why not get in touch with one of our members and see how they can help you in 2025.
