The Importance of Warehouse Safety: Lessons from Racking Incidents

Introduction

In 2016, a warehouse in Shropshire made national headlines when high-bay pallet racking collapsed under the weight of stacked cheese. A forklift operator became trapped under tonnes of Red Leicester and cheddar for nearly nine hours. Thankfully, he survived the ordeal.

While this incident drew attention due to the unusual cargo, many warehouse collapses happen every day without making the news. The risks to safety, operations, and business continuity are very real. More often than not, these risks are avoidable.

This article explores real-world examples, the legal duties facilities managers need to know, and answers to common compliance questions we frequently hear from clients.

Lessons from Racking Incidents

✉️ Improvement Notice: West Midlands (2020)

An HSE inspection found deteriorated pallet racking exposed to forklift damage. No formal inspection process or maintenance system was in place. As a result, the company received an Improvement Notice. This notice cited PUWER 1998 and Sections 2 and 3 of the Health and Safety at Work Act 1974.

"You have failed to take all reasonably practicable action to ensure that work equipment, specifically warehouse racking… has been inspected to maintain safety and ensure any deterioration or damage can be detected and remedied."

This serves as a reminder that it doesn’t take an injury to trigger enforcement actions. Awareness and compliance are essential.

What the Law Says

Under the Provision and Use of Work Equipment Regulations 1998 (PUWER):

• Racking is classified as work equipment.

• It must be maintained in an efficient state and inspected regularly.

  
  

It is crucial to understand that negligence regarding these regulations can lead to severe consequences for both the employees and the management.

Common FAQs from Facilities and Operations Teams

Do I really need to inspect my racking?

Yes. If it’s exposed to damage or wear—which most pallets are—then regular inspections are legally required under PUWER. It’s recommended to conduct these inspections annually.

How often should it be inspected?

While there’s no fixed schedule in the law, best practices suggest:

• Annual inspections by a competent person

• Weekly or daily visual checks by trained staff

  
  

Regular checks can help identify risks before they escalate into significant threats.

What counts as damage that needs action?

Bent uprights, missing beam locks, cracked welds, or misaligned frames all compromise safety. Even minor knocks can accumulate risk over time. Therefore, even if there are no visible signs of damage, an inspection is still advisable.

Can I delegate responsibility to a subcontractor or team member?

You can only delegate this responsibility if the individual is qualified and clearly assigned. However, the ultimate legal responsibility resides with the dutyholder.

Do I have to act if damage is minor?

Yes. If there's a chance that the minor damage could worsen or contribute to a collapse, it must be addressed immediately.

Good Practices to Stay Ahead of Risk

Maintaining a safe warehouse environment is crucial. Here are some best practices:

• Keep a log of all racking inspections and maintenance. Regular monitoring is vital to ensuring repairs are identified and addressed promptly.

• Train staff to report damage immediately. Quick reporting can prevent further issues.

• Display clear load limits on all racking. This helps staff understand weight regulations.

• Use rack protectors and impact barriers. These measures can mitigate damage from forklifts.

• Have a plan in place for remedial works. A solid action plan can ensure your team is prepared for any necessary repairs.

  
  

Following these practices not only increases safety but also helps maintain compliance with various regulations.

How KTCS Can Help

At KTCS, we support warehouse and logistics teams to stay safe, compliant, and operational. Our services include:

• Arranging expert racking inspections

• Reviewing your inspection and reporting systems

• Coordinating remedial works

• Supporting compliance with PUWER and Health and Safety regulations

  
  

Our expertise ensures your operations run smoothly without compromising safety.

Ready to Review Your Setup?

If you're unsure when your last racking inspection took place or if you're facing pushback on repair budgets, it’s time to act.

Contact kevin@ktcsltd.com or visit ktcsltd.com to discuss your site needs. Ensuring the safety and compliance of your warehouse is not just a legal obligation; it's a commitment to your employees and business continuity. Don’t wait until it’s too late.