What an Expert Pallet Racking Inspection Actually Covers
If you've never had a formal pallet racking inspection, you might be wondering what it actually involves. A visual check? A tick-box exercise? Something that takes an hour and produces a report you file away and never look at again?
A thorough inspection carried out by a SEMA Approved Rack Inspector (SARI) is none of those things. Here's what it actually covers.
Who carries out the inspection?
A SEMA Approved Rack Inspector (SARI) is a qualified inspector who has been assessed against the SEMA (Storage Equipment Manufacturers' Association) standard. SEMA is the UK trade association for the storage equipment industry, and the SARI qualification is the recognised standard for racking inspection in the UK.
At True Space Solutions, all inspections are carried out by a SARI. That means the inspection is conducted against current SEMA guidelines and HSE requirements — not a proprietary checklist or a simplified version of the standard.
# What Components Are Checked During a Pallet Racking Inspection?
Pallet racking can look like a fairly simple structure, but it is made up of several connected components. Each has a specific purpose, and they all need to work together to support the stored loads and keep the racking stable.
During a racking inspection, we check these components for impact damage, distortion, corrosion, missing parts and unauthorised alterations. We also consider how the racking is configured and being used.
Uprights
Uprights are the vertical sections of the racking. They support the beams and transfer the stored loads down through the baseplates and into the warehouse floor.
Because uprights are often exposed to forklift movements, they are one of the most commonly damaged components. We check for bends, twisting, dents, corrosion and local buckling.
A bend is generally a smooth curve away from the upright’s original position. Local buckling is a more concentrated fold, crease or distortion that changes the shape of the upright section. This distinction is important because damage can affect how the upright carries compression and transfers loads through the structure.
Beams and beam end connectors
Beams support the pallets and transfer their weight into the uprights. Under load, beams are mainly subjected to bending and shear forces.
Some beam deflection under load is normal, but excessive or permanent deformation may indicate damage or overloading. We check beams for vertical or horizontal bending, twisting, dents, damaged seams and cracked welds.
At each end of the beam is a beam end connector. This connects the beam to the upright and transfers the load into the frame. We check that the connector hooks are correctly engaged and that there is no bending, distortion or damage to the connector, welds or upright perforations.
Beam connector locks
Beam connector locks, sometimes called beam safety locks, help prevent a beam from being accidentally dislodged by an upward force.
During an inspection, we check that the correct locking device is present, properly engaged and undamaged. If a lock is missing or disengaged, the surrounding beam connector and upright should also be checked for damage before a replacement lock is fitted.
Frame bracing
Horizontal and diagonal braces connect the front and rear uprights to form a rigid frame. They help keep the frame square and provide stability across the aisle.
Depending on the racking design and the forces acting on it, braces may operate in tension or compression. We check for bent, twisted, buckled, missing or loose braces, as well as damage to their connections.
We also look for inconsistent or unrecognised bracing patterns. Frame bracing should be installed in accordance with the original manufacturer’s design, as removing or repositioning a brace can affect the stability of the complete frame.
Baseplates and floor fixings
Baseplates sit beneath the uprights and transfer the loads into the warehouse floor. Floor fixings secure the baseplates and help keep the uprights correctly positioned.
We check for bent or twisted baseplates, damaged welds, missing or loose fixings, poor shimming and cracking or deterioration in the surrounding floor.
Damage at floor level is often connected to an impact on the upright, so the baseplate, fixing and upright should be assessed together.
Run spacers
Run spacers connect two back-to-back rows of racking. They maintain the designed distance between the frames and help provide stability across the aisle.
We check that run spacers are present, secure, undamaged and positioned at the correct intervals. Missing or incorrectly spaced run spacers may affect how the installation behaves and should be checked against the original design or manufacturer’s guidance.
Upright splices
On taller racking installations, the uprights may be made from upper and lower sections joined by an upright splice.
The splice keeps the two sections aligned and transfers loads from the upper upright into the section below. We check for missing fixings, misalignment, corrosion, distortion and damage around the connection.
Because splices and high-level beam connectors can be difficult to inspect properly from the warehouse floor, a closer at-height inspection may sometimes be recommended.
Looking beyond individual components
A racking inspection is not limited to visible component damage. We also consider the complete storage system, including:
- Load notices and stated capacities
- Beam levels and configuration
- Pallet size, condition and positioning
- Pallet and load clearances
- Support bars, mesh decks and timber decking
- Racking protection
- Evidence of overloading
- Changes made since the original installation
- Housekeeping and operational practices
Damage to one component can affect how forces are transferred through the adjoining parts of the structure. That is why pallet racking should be inspected as a complete system rather than as a collection of separate components.
How are findings classified?
Every finding is classified against the SEMA risk rating system:
Red Risk — High levels of damage requiring the affected area to be immediately offloaded and isolated from use until repairs are completed.
Amber Risk — Damage requiring remedial work within 4 weeks. Immediate offloading is not required, but once affected pallet locations are emptied they must not be refilled until repairs are completed. If not repaired within 4 weeks, the item becomes Red Risk.
Green — Damage falls within SEMA limits. Record it and review it at the next inspection — Green does not mean the damage should be ignored.
This classification system gives you a clear picture of what needs immediate attention, what needs to be scheduled, and what requires monitoring.
What does the report include?
Every inspection from True Space Solutions produces a full written report that includes observations and recommendations on:
- A summary of damage findings by risk classification
- Summary of the operation
- Layout drawing and racking specification
- Housekeeping
- Pallet placement
- Protection to walkways
- Rack protection
- Photographic evidence
- Information on the plausibility of load notices
- Appendix section with good practice guidance
- Photographic evidence
The report is designed to be shareable — with your team, your insurers, or an auditor. It gives you a documented record of the condition of your racking at the time of inspection.
What happens after the inspection?
At True Space Solutions, we don't just hand over a report and disappear. We're available to discuss the findings, explain what they mean in practical terms, and advise on the most efficient way to address them.
If repairs are needed, we can complete them — quickly, to manufacturer specification, with minimal disruption to your operation. We're not just an inspection company. We're the team that helps you move from identifying the problem to getting it resolved.