Can I continue using racking classified as Amber risk?

Immediate offloading is not normally required for Amber damage. Once an affected pallet location has been emptied, however, it should not be reloaded until the remedial work is complete. Amber damage that remains unresolved after four weeks should be redesignated as Red risk.

Can DC repair damage identified by another inspection company?

Yes. We can review a report prepared by another competent inspector, including a SARI inspection report. If it contains enough information about the racking system and damage, we may be able to provide a quotation without carrying out another inspection.

Will the repairs restore the original load capacity?

This depends on the components, repair specification and condition of the surrounding racking. The original capacity should not be assumed if the configuration or component specification changes. Where required, the capacity and load notice should be reviewed before the racking returns to use.

What records do I get after the repair?

DC provides a completion record covering the agreed work, the components repaired or replaced and any further recommendations. These records can be kept with the original inspection report and your racking maintenance information.

How quickly can you get to site?

Urgent repairs can be handled through DC Rapid-Fix. Once the damage has been verified, work is booked within 24 hours and installers can be on site within five days anywhere in the UK.

Racking Repairs Following an Inspection

Damaged Racking Flagged? Here's What to Do Next

Your racking inspection report has flagged damage. The action you take next helps protect employees, control risk and keep your warehouse operational.

DC Space & Storage Solutions carries out racking repairs across the UK, taking manufacturer instructions, BS EN 15635 and relevant SEMA guidance into account. Through our Rapid-Fix service, work is booked within 24 hours once the damage has been verified, with engineers on site within five days. Each completed job is documented, giving duty holders a clear record of the action taken.

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What Happens After a Racking Inspection Fails?

A SARI inspection can identify damage to uprights, beams, bracing, frames, base plates and locking devices, with each finding classified by risk. The report is not the end of the process.

PUWER requires work equipment to be maintained in a safe condition. HSG76 and the SEMA traffic-light classifications set out the action required for different levels of racking damage.

Three things may need to happen:

Immediate action on serious damage. Red risk racking must be offloaded and taken out of use straight away.
Scheduled repairs. Amber risk damage should be repaired as soon as possible. Once an affected location is emptied, it should not be reloaded.
A documented record. Keep details of what was found, what action was taken and when the work was completed.

We turn inspection findings into completed, documented repairs. Send us your report and we can quote against the items flagged, free of charge.

Red, Amber and Green Risk Classifications Explained

SEMA’s traffic-light system classifies racking damage according to its severity and the action required.

Red risk: Red indicates a critical level of damage. The affected racking must be offloaded immediately, isolated and taken out of use until the required repair or replacement work has been completed.

Amber risk: Amber indicates hazardous damage requiring remedial work as soon as possible. Immediate offloading is not normally required, but once an affected pallet location has been emptied, it must not be reloaded until the work is complete. If Amber damage has not been rectified within four weeks of its original classification, it should be redesignated as Red.

Green risk: Green damage is within the limits that do not normally require immediate repair or a reduction in carrying capacity. It should still be recorded, identified for re-examination and monitored during future inspections.

If your report contains Red or Amber findings, action is already required.

How Quickly Must Racking Be Repaired?

Red risk racking must come out of use immediately and remain isolated until the required work is complete.
Amber damage should be repaired as soon as possible. Once the affected location has been emptied, it should not be reloaded. If the work is not completed within four weeks of the original classification, the damage should be redesignated as Red.
Green damage does not have a fixed repair deadline, but it should be recorded and monitored.

Four weeks can pass quickly once quotations, approvals and contractor lead times are taken into account. Our Rapid-Fix process helps reduce delays, with jobs raised in as little as eight minutes, damage verified within 30 minutes, work booked within 24 hours and engineers on site within five days. First-visit resolution is provided wherever possible.

Pallet Racking Repair vs Replacement

Not every flagged component requires a complete section of racking to be replaced, and not every damaged upright can be repaired. The correct action depends on the affected component, the extent of the damage, the manufacturer and the racking system.

Localised repair work may involve replacing an individual beam, brace, locking device or other component. A damaged upright may need replacing or may be suitable for a recognised repair method that is appropriate for the identified system and accepted by the manufacturer.
More extensive replacement may be needed when damage affects several connected components, the racking system is obsolete or suitable matching parts are no longer available. Repeated impact damage may also indicate a problem with the layout, protection, clearances or handling practices that repairs alone will not resolve.

Our recommendations are based on the condition of the racking, the level of risk and the requirements of the site. Components are checked for compatibility, and manufacturer instructions and relevant SEMA guidance are taken into account. If the original configuration changes, the load capacity and load notice may also need to be reviewed.

Are You PUWER Compliant? Your Legal Obligations After an Inspection

Pallet racking is work equipment under the Provision and Use of Work Equipment Regulations 1998. This places several duties on the employer:

Racking must be maintained in an efficient state, in efficient working order and in good repair under Regulation 5.
Racking must be inspected at suitable intervals where deterioration could create a risk, and after events that may have affected its safety.
Inspection results must be recorded and kept at least until the next inspection.

HSE guidance HSG76 recommends an expert inspection by a technically competent person at intervals of no more than 12 months, supported by regular visual checks and immediate damage reporting. A SEMA Approved Racking Inspector is trained and assessed to carry out this expert inspection.

An inspection alone does not address the damage it identifies. Failing to control serious damage or complete the required remedial work could leave unsafe equipment in use and may lead to enforcement action, particularly following an incident or investigation.

Our repair documentation records the damaged components, work completed and any further action recommended, helping you maintain a clear safety and maintenance record.

Book Your Post-Inspection Repairs

Don't let an amber classification turn red. Get in touch today and we will talk you through the next steps.

Our Racking Repair Process

For fast repair work, DC Rapid-Fix provides a priority service for urgent racking damage.

Send us your inspection report. We review the flagged items and prepare a free quotation. If you do not have a report, we can arrange an inspection by a SARI first.
Damage reviewed. We assess the findings, identify the racking system and confirm the components required.
Work arranged. We schedule the repair and confirm any unloading, access or operational requirements with your team.
Repairs completed. Our engineers use suitable components and documented methods, with work planned to limit disruption to picking and loading. We aim to resolve the repair on the first visit wherever possible.
Documentation issued. You receive a record of the components repaired or replaced, the completed work and any further recommendations.

For multi-site operators, the same process can be managed across every location, with consistent scheduling, progress updates and completion records.

Why warehouses across the UK trust us

• More than 30 years of experience in pallet racking and warehouse storage systems
• SEMA Approved Member at Advanced level
• SEIRS-qualified installers
• ISO 45001, ISO 9001 and ISO 14001 certified
• SafeContractor accreditation and the Altius Assured Award
• SARI racking inspections and RoSPA-certified Rack Safety Awareness Training available
• Nationwide Rapid-Fix coverage, with engineers on site within five days once damage has been verified
• Experience supporting builders’ merchants, cold stores, food production sites, pharmaceutical facilities and other warehouse environments

Frequently asked questions

Repair Following Inspection

Our Company Overview

Our Pallet Racking Manual