Should I buy second hand racking?
A question we’re frequently asked at SEMA is whether it’s okay to buy second-hand racking. After all, there are plenty of suppliers offering the benefits of their ‘reliable’ second-hand pallet racking, so surely it’s safe.
However, with little traceability or certainty around its history, your second-hand racking can quickly lead to a poor investment. One that ends up costing more than purchasing new and, more worryingly, compromises employees’ safety.
The Appeal of Second Hand Racking
For warehouse owners and managers there may seem to be an apparent advantage when buying second-hand.
It’s easy to see why many businesses view this as an appealing option with used racking typically costing less.
Cost may be the main driver for buying second hand but for SEMA, the problem lies in the story your pallet racking can’t tell you. What is the storage system’s history? Where and how was it previously used? Was it properly maintained and repaired? How was it handled and stored once dismantled? Without verifiable answers to these areas you risk buying a structure that is damaged, impossible to repair, or in worst case scenarios poses a serious safety risk.
Traceability is incredibly important towards delivering safe and cost-effective racking. Yet few suppliers can offer this on used racking and a lot of customers simply trust the sales person. You wouldn’t buy a car without a full MOT or service, why take a different approach with your pallet racking?
Let’s break down each of these problem areas and explain how it impacts on your perceived cost-savings.
Who designed and supplied the second hand racking?
When designing the racking, was the specification accurate and appropriate for its intended use?
In the UK, racking should meet the requirements set out in either SEMA Design Codes or European Code EN 15512. These standards provide assurances on the quality of your racking by defining critical parameters. This includes structural analysis, the types of loads you must consider, how to test components and the safety factors required. When designing a racking system, the designers ensure it meets the requirements needed for the weight and type of stock you are loading on the structure. While Design Codes are required for new storage systems, it is not mandatory to redesign second-hand racking to these standards.
Now your second-hand racking is creating two issues. First, did the original company meet the requirements of the Design Codes? If not, it could have caused unnecessary wear and tear that has weakened your second-hand structure. You also have no assurances the company supplying your used racking is designing to the highest quality and safety levels.
One final consideration is the Load Notice. Correctly loading a pallet racking system is essential to prevent workplace accidents and reduce the risk of collapse. When purchasing new racking, your supplier should fix a Load Notice to the structure, clearly stating the maximum load and any required load configurations. Is your used pallet racking supplier providing you with this essential safety sign. More importantly, is the information on the Load Notice correct?
How has the racking been installed?
While the installation of your storage solution might not seem significant, it plays a vital role in upholding the long-term safety and performance of the structure. Installers have to meet the exact specification of the racking design.
One problem within the racking installation industry is that not all suppliers check the credentials of their installer. This is a significant problem when you consider that a lot of installers still learn ‘on the job’. Over time it is very easy for them to pick up bad habits. Even worse they might not know the correct methods in the first place.
If the original installer hasn’t followed the racking designer’s specification or missed crucial elements during installation it can cause unnecessary stress on the structure. If a part of the racking fails above your employees’ heads, it will result in heavy stock crashing down to the floor where your employees are working. Unlike a car, which is fitted with multiple safety measures, in case of an accident, racking doesn’t offer such protection.
The safety of your warehouse racking now relies correct installation in your warehouse but also accurate installation when new.
Was the racking correctly maintained?
At SEMA we always advise following a rigorous approach to racking safety. The process starts by appointing a member of your team who becomes the Person Responsible for Racking Safety (PRRS). It is their role to check racking inspections and maintenance records are complete, analyse racking damage data, identify if regular issues are occurring and implement remedial actions.
You then need to adopt a three-step approach to racking inspections. Every day, employees working in areas with racking should identify and report on any damage they find. Next, send a competent team member on a training course, such as our Rack Safety Awareness course. This will instruct them on how to conduct the Visual Inspection. This inspection will look for damage on the structure, check correct loading is being followed and write up a report that forms part of your official maintenance records. Finally, at least once a year, a qualified inspector, such as a SEMA Approved Racking Inspector (SARI), must inspect your racking.
While you know this happens if you buy the racking new, you need to check the following when purchasing second-hand:
- Were inspections carried out according to HSE and SEMA recommendations?
- Did the PRRS follow correct steps?
- Did the employee undertaking the in-house inspections perform them according to the risk assessment? Were they trained for the role?
- Do the inspection reports cover the lifetime of the equipment?
- What were the qualifications of the inspector undertaking the Expert Inspection?
- Was the Expert Inspection a ‘Damage-only’ report, which only shows the damage and its possible location, or an inspection by a SARI showing detailed information and a timescale for repair work.
You could easily be purchasing used pallet racking that is over 10 years old. That’s a lot of checking up on inspection records to be done!
Racking Repairs
An inspection report is only as good as the actions taken afterwards. With second hand racking you have limited knowledge on the work that was carried out, whether it was approved by the manufacturer and if it met industry standards. For example, you will see there are several bulletins written by our technical industry experts advising on permissible work allowed on racking. For example, SEMA Technical Bulletin No. 09 which warns against cutting down and rewelding beams on racking. Yet this is a common practice!
If you can’t confirm whether repairs were made correctly – or approved by the manufacturer – you’re buying an element of risk.
Corrosion?
This leads us to the structural integrity of your structure. The metal in your racking should be highly durable and last a lifetime. However, there are some factors which can weaken the structure. If it’s been under a warehouse roof, there is some comfort in knowing that this protected it from the elements and it is less likely that internal rust will have occurred. But you can’t be certain.
You should also consider what happened after the racking was dismantled. With warehouse costs at a premium, it’s not uncommon to store the old racking outside until it’s sold on. This causes a problem when you realise not all racking has been manufactured to be kept outside. This means exposure to the elements will cause damage and corrosion that weakens the steel.
While your racking might look ‘fine’ on the surface you can’t be sure what is sitting beneath the painted exterior. Yes, there are ways you can check if there is deterioration to the uprights and the inside of beams, but the process is expensive, time-consuming and will quickly minimise any cost savings you might have made from buying second-hand.
A Cost-Effective Solution?
If the safety of your warehouse isn’t enough of an incentive to not buy second-hand, you might also want to consider the cost-effectiveness of your purchase. Upfront costs are undoubtedly cheaper over new racking, but ongoing costs could very quickly outweigh the initial savings.
With second-hand systems, you have very little idea on its history. You’ll have little idea on the age of the structure, how it has been maintained and the amount of wear and tear it has suffered. This can quickly lead to more frequent repairs on second hand racking. Add up all that repair work it will quickly reduce the cost-effectiveness of a second hand structure compared to new.
Then there’s the issue of which manufacturer supplied the racking. If a part needs replacing, you must only use approved products. Yet if the manufacturer has discontinued the range will you know where to find replacements. Reputable manufacturers will provide ongoing support for their racking with compatible parts but there are no guarantees with other suppliers. Suddenly, your ‘cheap’ second hand racking is a wasted investment, and you’ll need to replace the whole structure.
Why SEMA don’t think second hand racking is worth the risk
At SEMA, we understand the pressures on warehouse owners to cut costs but at what price. Second-hand racking might deliver an upfront bargain. However, the lack of traceability, the cost of ongoing repairs and a reduced lifespan can quickly outweigh the short-term savings.
