Are there specific industry standards for pallet rack inspections?

Yes. In the UK, pallet rack inspections are guided primarily by BS EN 15635:2008, which covers the use, inspection and maintenance of steel static storage systems. Inspections should also take account of the Health and Safety at Work etc. Act 1974, the HSE guidance in HSG76 Warehousing and storage: A guide to health and safety, and the Provision and Use of Work Equipment Regulations 1998 (PUWER), where applicable.

These requirements work together rather than operating as a single certification scheme. BS EN 15635 provides the recognised technical framework for managing pallet storage systems, while legislation places duties on employers and those responsible for workplace equipment. The responsible person must ensure that storage equipment is suitable, properly installed, used as intended, maintained and inspected by people with appropriate competence.

What BS EN 15635 covers

BS EN 15635 sets out a practical system for keeping pallet storage equipment safe throughout its working life. Its main principles include:

• appointing a Person Responsible for Racking Safety (PRRS) to oversee safe use and maintenance;
• following the equipment supplier’s instructions, load notices and operating limitations;
• carrying out regular visual checks by suitably instructed site personnel;
• arranging a documented inspection by a technically competent expert at intervals based on the site’s risk, with the interval not exceeding twelve months;
• reporting damage promptly and assessing whether affected bays or components need to be unloaded or taken out of service;
• recording findings, corrective actions and evidence that repairs have been completed properly; and
• reviewing the system after changes to layout, loading, vehicles, working practices or building conditions.

The standard uses a risk-based approach. It does not mean that every warehouse must follow an identical inspection schedule. Traffic levels, vehicle type, pallet condition, operator behaviour, loading patterns, previous damage, environmental conditions and the design of the installation should all influence the frequency and scope of checks.

How the supporting standards fit in

Other European standards may apply to the design and installation of the storage system. For example, BS EN 15629 addresses the specification of storage equipment, BS EN 15620 covers tolerances, deformations and clearances, and BS EN 15512 deals with the structural design of adjustable pallet storage systems. These standards are particularly relevant when assessing whether an installation was designed, supplied and installed for its intended loads and operating conditions.

An inspection is not normally a substitute for the original structural design calculations or installation documentation. Where load information is missing, the layout has changed or the equipment has been altered, further technical assessment may be needed before safe loading can be confirmed.

What an inspection should verify

A competent inspection should consider the complete installation and its use, not just isolated upright frames. Typical checks include:

• uprights, frames, bracing, footplates, anchors and protective guards;
• beams, connectors, locking devices and visible signs of distortion;
• flue spaces, clearances, pallet support arrangements and load distribution;
• loads displayed against the stated configuration and the condition of pallets;
• aisles, access routes, lighting, housekeeping and vehicle interaction;
• evidence of impact, corrosion, missing components, unauthorised alterations or overloading; and
• the effectiveness of existing controls, including reporting arrangements and staff awareness.

Damage is commonly categorised by severity so that the site can prioritise action. Serious damage may require the affected area to be unloaded immediately and kept out of use until a suitable repair or replacement is completed. Less severe damage still needs to be recorded, monitored and addressed within a defined timescale. The inspector should explain the required action clearly rather than leaving the site to interpret a technical observation.

Legal duties and PUWER

The Health and Safety at Work etc. Act requires employers to protect employees and others affected by their work. This includes providing safe equipment, suitable systems of work, information, instruction, training and maintenance. PUWER may apply because pallet storage equipment is work equipment; where it does, it must be suitable, maintained and inspected when deterioration could create a significant risk.

HSG76 is HSE guidance rather than a British Standard or regulation. It explains good practice for warehouse operations, including traffic management, safe stacking, vehicle control, equipment maintenance and the prevention of falling loads. Following recognised guidance can help demonstrate that risks have been assessed and controlled, although the exact arrangements must reflect the conditions at the individual site.

What records should be retained

Inspection records should identify the installation inspected, the date, the person or organisation carrying out the inspection, the defects found, the risk classification, recommended actions and the person responsible for closing them. Keep the report alongside relevant layout drawings, load notices, previous inspection findings, repair records and evidence of any changes.

Records are most useful when they support day-to-day control. Staff should know how to report impacts and defects, damaged areas should be clearly identified, and repairs should be carried out using compatible components by suitably competent personnel. A damaged component should not simply be straightened, welded or modified without an appropriate technical decision.

Practical compliance advice

To align your inspection process with recognised UK practice, maintain a current layout and load information, appoint a responsible person, provide appropriate operator instruction, complete routine visual checks, arrange the required expert inspection and act promptly on findings. Review the process whenever there is a change in vehicles, stock, loading, layout, equipment or working methods.

Industry standards provide a framework, but compliance depends on how effectively the system is managed in practice. A detailed inspection report, prompt control of damage and clear evidence of completed remedial work are essential parts of keeping pallet storage equipment safe, compliant and operational.