What specific SEMA guidelines should a SEMA Approved Inspector be knowledgeable about to ensure thorough warehouse racking inspections?

SEMA Approved Inspectors should be knowledgeable about the SEMA Code of Practice for the Use of Static Pallet Racking, the SEMA guidance for conducting pallet racking inspections and the requirements of BS EN 15635. Together, these documents explain how to assess the condition, configuration, loading, damage and use of warehouse racking, how to classify risks and how to recommend suitable corrective action.

The SEMA guidance is not simply a checklist for visible damage. It provides a structured approach to deciding whether a warehouse racking system remains suitable for its intended use. An inspector should apply the guidance alongside the original design information, manufacturer instructions, site procedures and relevant workplace health and safety requirements.

Key SEMA guidance areas include:

• Inspection scope and method: The inspector should understand how to carry out a systematic visual examination of accessible parts of the warehouse racking system. This normally includes uprights, frames, beams, bracing, baseplates, safety locks, guards, connectors, decking and other load-supporting or protective components.
• System identification: The inspection should establish what type of warehouse racking is installed, how it is configured and whether the current arrangement matches the intended design. This includes checking beam levels, bay layouts, component types and any changes made since installation.
• Load information: SEMA guidance places importance on clear and accurate load notices. An inspector should check whether the notice is present, legible and consistent with the installed configuration, pallet dimensions, beam arrangement and permissible loads. Missing, damaged or inaccurate load information should be recorded as a safety concern.
• Damage assessment: The inspector should be able to recognise damage such as bent or twisted uprights, damaged bracing, distorted beams, displaced components, damaged safety locks, loose fixings, impact marks and deterioration caused by corrosion. They should assess the seriousness of the defect rather than treating every defect in the same way.
• Risk classification: SEMA inspection practice uses risk-based categories to help determine the urgency of action. Lower-level defects may require monitoring and planned attention, while more serious damage can require prompt repair, unloading or isolation of the affected area. A competent inspector must understand when a defect has moved beyond acceptable monitoring.
• Stability and structural condition: The inspector should consider whether frames are plumb and stable, whether bracing and connections remain effective, and whether the floor, anchors and baseplates are providing suitable support. The condition of individual parts must be considered in relation to the stability of the complete warehouse racking system.
• Protection from impact: Upright guards, end-of-aisle protection and other protective measures should be checked for presence, suitability and condition. Protection should be considered in relation to the movement of vehicles, pallets and handling equipment around the warehouse racking.
• Correct use and loading: The inspection should identify overloading, unevenly distributed loads, unsuitable pallets, loads projecting into aisles, incorrect beam positioning and storage practices that differ from the design assumptions. Operational misuse can create a significant risk even where the steel components appear undamaged.
• Unauthorised alterations: Cutting, drilling, welding, removing bracing, changing beam levels or substituting components can affect the original design. SEMA guidance requires the inspector to identify changes that may invalidate the design or manufacturer’s instructions and to recommend review by a suitably competent person where necessary.
• Housekeeping and surrounding conditions: The inspection should take account of blocked aisles, debris, poor visibility, inadequate lighting, damaged floors and other conditions that may increase the likelihood of impact or unsafe use. These issues may not be defects in the warehouse racking itself, but they can directly affect its safe operation.

Risk categories and corrective action

A SEMA Approved Inspector should be able to explain the reason for each risk classification and link it to a practical action. For example, a minor defect may be recorded for monitoring or planned maintenance, whereas serious damage may require the affected bay to be unloaded and taken out of service until it has been repaired or otherwise made safe. The inspector should not rely on a colour or category alone; the report should identify the location, defect, risk and required response clearly.

Where immediate action is necessary, the site should receive clear instructions on isolating the affected area and preventing further use. Repairs should be completed by a competent repair provider using suitable components and an appropriate method. Replacing a damaged part without investigating the cause, such as repeated vehicle impact or incorrect loading, may leave the underlying risk unresolved.

BS EN 15635 and related requirements

Although the SEMA Code of Practice is central to a SEMA-focused inspection, the inspector should also understand BS EN 15635, Steel static storage systems — Application and maintenance of storage equipment. This standard addresses safe use, user responsibilities, damage reporting, inspections, maintenance and the need for a technically competent person to assess warehouse racking condition.

In practice, this means understanding the difference between:

• routine observations made by warehouse staff during normal operations;
• regular internal checks and reporting of damage; and
• a formal expert inspection by a competent person, normally arranged at intervals of no more than twelve months or sooner where the risk assessment, operating conditions or previous findings require it.

The inspector should also know when an additional assessment is appropriate, including after a significant impact, alteration, change of load, change of use, relocation or discovery of repeated damage.

Design information and manufacturer requirements

SEMA guidance should be applied with the available design drawings, load calculations, component details and manufacturer’s instructions. These documents can establish the intended capacity and configuration of the warehouse racking. If the information is unavailable or the installed arrangement cannot be verified, the inspector should record that limitation and avoid making unsupported assumptions about capacity.

An inspection is not normally a substitute for a full structural design check. Where there are unusual loads, substantial alterations, missing design records, incompatible components or doubts about the original specification, the matter may need to be referred to the manufacturer, designer or another suitably qualified structural specialist.

What a well-informed inspector should record

A thorough report should identify the warehouse racking inspected, the areas covered, the inspection date, access limitations, observed defects, risk classifications and recommended actions. Findings should be located precisely using bay references, photographs, marked-up layouts or another method that allows the site team to find the affected area without ambiguity.

The report should distinguish between damage requiring repair, conditions requiring monitoring and matters requiring further technical investigation. It should also note positive controls, such as visible load notices, effective protection and suitable housekeeping, where these have been checked. Clear records allow Able Racking and the customer’s responsible person to prioritise repairs, verify completion and track recurring problems over time.

Practical application on site

A SEMA Approved Inspector should combine the written guidance with careful observation and professional judgement. They should ask how the warehouse racking is used, review previous inspection findings, speak to the responsible site contact and consider whether the operating environment has changed. Their role is to identify risks before they result in failure, support proportionate corrective action and help the customer maintain a safe, compliant and efficient storage system.