At-Height Racking Inspections: When Is a Closer Look Needed?

A standard SARI inspection is a systematic walk of the entire racking installation — every aisle, every bay, every upright and beam assessed against SEMA guidelines. For most warehouses, that covers everything that needs to be covered.

But not every warehouse is the same.

In high-bay facilities, or in installations where racking has been in place for many years without a formal inspection, there are components that a ground-level assessment simply cannot reach. Upper-level uprights. Rear-face damage on tall frames. Bracing connections at height. Components that are structurally significant but invisible from the floor.

That's when an at-height inspection becomes the right call.

What a standard inspection can and can't see

A ground-level SARI inspection is comprehensive for the components it can access. Our inspector works methodically through every aisle, assessing uprights, beams, connectors, base plates, and bracing at accessible levels.

What it cannot reliably assess is damage that is:

• On the upper sections of tall uprights — in a high-bay warehouse, the top third of a frame may be 8–10 metres above floor level
• On the rear face of racking — particularly in back-to-back installations where the rear of one run faces the rear of another, with no aisle access
• On bracing connections at height — cross-bracing and spine bracing at upper levels can sustain damage that isn't visible from below
• On beam connectors at the highest levels — sheared or cracked connectors at height may not be detectable without close inspection

In a warehouse with relatively low racking — say, three or four beam levels — the difference between what can be seen from the floor and what can't is limited. In a high-bay facility with six, eight, or ten beam levels, the gap is significant.

When an at-height inspection is appropriate

Not every warehouse needs an at-height inspection. The decision depends on a combination of factors:

Racking height — The higher the racking, the more significant the gap between what a ground-level inspection can assess and what it can't. As a general guide, warehouses with racking above approximately 6 metres should consider whether an at-height assessment is appropriate.

Throughput and forklift activity — High-throughput facilities with frequent forklift movements accumulate impact damage faster. In a busy distribution centre, upper-level uprights can sustain damage from reach truck masts, counterbalance trucks operating at height, or loads that shift during putaway.

Age of installation — Racking that has been in place for many years without a formal inspection is more likely to have accumulated undetected damage at all levels, including at height.

Previous findings — If a ground-level inspection has identified a pattern of impact damage at lower levels, it's reasonable to ask whether similar damage exists at height. Impact events that affect lower uprights often affect the full height of the frame.

Operational history — If the warehouse has had a significant incident — a forklift collision, a partial collapse, a load shift — an at-height inspection may be appropriate to assess whether the event caused damage beyond what was visible at ground level.

What an at-height inspection involves

An at-height inspection uses a powered access platform — a MEWP (mobile elevating work platform) — to allow the inspector to assess racking components at height, at close range.

This is not a cursory look from a cherry picker. The inspector works systematically through the installation at height, assessing the same components they would assess at ground level: uprights, beams, connectors, bracing, and base connections. The difference is that they can see them properly.

Everything identified during the at-height assessment is documented in the same way as a ground-level finding — photographed, classified by risk level (Red, Amber, or Green), and included in the written report.

The at-height inspection is carried out safely, in accordance with working at height regulations. Our team holds the relevant qualifications and operates the access equipment correctly.

What happens when damage is found at height

Finding damage at height is not unusual. In many cases, it's the reason the at-height inspection was commissioned in the first place.

Red Risk findings at height require the same response as Red Risk findings at ground level: the affected bay should be unloaded and access restricted until the repair is completed. The fact that the damage is at height doesn't change the risk classification — it changes the complexity of the repair.

Repairing damage at height requires the same access equipment used for the inspection. At True Space Solutions, we carry out repairs at height as well as inspections — so if our at-height assessment identifies defects, we can address them. You don't need to manage a separate contractor for the repair work.

The case study

Our Bicester case study is an example of what an at-height inspection can find. The client had a high-bay installation that had been in use for a number of years. A ground-level inspection had identified defects at accessible levels. The at-height assessment revealed additional damage on upper-level components that had not been visible from the floor.

The findings were documented, classified, and addressed. The client now has a complete picture of their racking's condition — not just the part that was visible from the ground.

Is an at-height inspection right for your warehouse?

If you manage a high-bay facility, or if your racking has been in place for a number of years without a formal at-height assessment, it's worth considering.

The cost of an at-height inspection is higher than a standard ground-level assessment — access equipment adds time and resource. But the cost of not knowing what's at the top of your racking is potentially much higher.

Talk to us about your warehouse and we can advise whether an at-height inspection is appropriate for your installation.