But compliance issues with warehouse racking regulation systems often don’t show up until something goes wrong. And by then, the disruption, cost and pressure can be far greater than most sites expect.

Here, we look beyond the obvious inspections and routine tick box exercises. It focuses on common areas where compliance really breaks down, why those gaps appear, and how UK warehouses can manage warehouse racking regulations in a way that supports growth rather than holding it back.

What compliance with UK warehouse racking regulations really means

There isn’t a single piece of legislation called “warehouse racking regulations”. Instead, compliance sits across several UK health and safety laws that place ongoing duties on employers and site operators.

The main ones include:

• The Health and Safety at Work etc. Act 1974 (HSWA) – the overarching duty to protect employees and others.
• PUWER (Provision and Use of Work Equipment Regulations 1998) – which covers racking as work equipment.
• The Management of Health and Safety at Work Regulations 1999 (MHSWR) – requiring risk assessments and safe systems of work.

Together, these laws make it clear that warehouse racking regulation systems must be safe, suitable for their use, and properly maintained.

The keyword here is ongoing. Compliance is not a one off event. A racking inspection carried out last year does not guarantee compliance today if the way the warehouse operates has changed. And in most busy UK warehouses, it almost certainly has.

The Health and Safety Executive (HSE) reinforces this approach in its guidance on warehousing and storage, which can be found here. 

Why you need more than just inspections

Regular rack inspections are essential. But inspections alone don’t equal compliance with warehouse racking regulations.

There is an important difference between:

• The condition of the racking – is it damaged, overloaded, or incorrectly installed?
• The management of the racking – how it is used day-to-day, who controls changes, and how risks are reassessed.

An inspection tells you what the pallet racking system looks like on a particular day. It does not automatically address how pallets are selected, how loads change, or how drivers interact with the system.

Even after a professional inspection, legal responsibility does not change. The duty to manage risk still sits with the employer or site operator. If damage is noted but not acted on through rack repair or replacement, or if operating practices drift away from the original design, compliance gaps can quickly open up.

Potential responsibility gaps

One of the most common issues with warehouse racking regulations is uncertainty over who is responsible for what.

The most common gaps we find include:

• Senior management assuming inspections cover all legal duties.
• Site managers believing design limitations sit with the installer.
• Operators making informal adjustments to “get the job done”.
• Multi-site businesses applying standards inconsistently across locations.

Legally, responsibility usually sits with the employer, but practical control is often shared across teams. Without clear ownership, things slip such as load notices not being updated, damage reports that don’t get escalated, and temporary fixes becoming permanent solutions.

Across multiple sites, this risk multiplies. One warehouse may be well managed, while another quietly drifts out of alignment with warehouse racking regulation systems that were originally signed off.

Impact of operational changes on compliance

This is where many hidden compliance gaps start. Warehouses evolve faster than their racking assessments.

The most common changes are usually:

• Increased pallet weights
  
  Heavier loads can exceed original design limits. Regulations require risks to be reassessed when loads change, not when something fails.
• New SKUs or different load types
  
  Non-uniform or unstable loads behave differently in racking. That changes the risk profile.
• Changes to forklift type or reach height
  
  Different trucks introduce different impact risks and clearances, affecting racking safety.
• Temporary storage becoming permanent
  
  What starts as a short term overflow storage solution often stays. If it hasn’t been assessed, it’s a compliance gap.
• Racking moved or altered without reassessment
  
  Even small layout changes can invalidate original calculations and load notices.

Under UK warehouse racking regulations, any of these changes trigger a duty to review risk assessments. Ignoring them doesn’t remove responsibility.

Training gaps & documentation

Training that doesn’t match reality

Operators and supervisors are often enrolled onto rack safety awareness training once and expected to adapt forever. In reality, equipment, stock and pressures change as a business grows and transforms.

Common issues include:

• Operators not understanding load limits.
• Supervisors unsure when to escalate damage.
• New starters copying informal workarounds.

Those workarounds often start as practical fixes. Over time, they become “how we do things here”, even if they undermine the warehouse racking regulation systems in place.

Documentation that doesn’t drive action

Paperwork really does matter, but only if it’s used.

Typical problems include:

• Inspection reports filed but not followed up.
• Damaged racking recorded but left in use.
• Load signage that’s missing, incorrect or out of date.

Clear documentation, visible signage and traceable actions are all part of compliance. They also make it far easier to run a warehouse that’s ready to scale without constant fire-fighting.

When non-compliance comes to light

Most sites don’t discover compliance gaps during calm periods. It usually happens after:

• A near-miss or accident.
• An insurance investigation.
• An HSE inspection or enforcement visit.

At that point, what could have been a planned review turns into an urgent disruption in order to comply. Stock has to move. Areas get closed. Costs rise quickly.

The frustrating part? In most cases, these issues are avoidable. The warning signs were there, but they were buried in day-to-day pressure.

How to close the gaps without overcomplicating warehouse racking regulations

Managing warehouse racking regulations doesn’t need layers of process or technical language. The most effective sites focus on a few fundamentals and apply them consistently.

Clear ownership of racking safety

Every site needs a named person responsible for racking safety. This is not just about organising inspections. It’s about knowing who:

• Reviews inspection reports
  
• Signs off changes to racking or layouts
  
• Has authority to stop unsafe use
  

Without clear ownership, issues are identified but not resolved, creating compliance gaps over time.

Reviews triggered by operational change, not just dates

Annual inspections are important, but they are not enough on their own. Compliance with warehouse racking regulations should be reviewed whenever the operation changes, including:

• Heavier pallets or different load types
  
• New SKUs or storage methods
  
• Changes to forklift type or reach height
  
• Racking moved, altered or reused
  

A simple review at the point of change helps ensure racking is still suitable for how it is being used today.

Training that reflects real warehouse activity

Training works best when it matches reality. Operators and supervisors need guidance that reflects:

• Busy shifts and peak periods
  
• Common handling risks
  
• What damage must be reported immediately
  
• When to stop using racking
  

When people understand why limits exist, unsafe workarounds are less likely to become standard practice.

Simple systems that lead to action

The strongest warehouse racking regulation systems are usually the simplest. Effective sites focus on:

• Clear, accurate load signage
  
• Easy damage reporting processes
  
• Inspection findings that are tracked and closed out
  
• Documentation that reflects the current setup
  

If systems are easy to follow, they are far more likely to be used consistently.

Compliance aligned with business objectives

When warehouse racking regulations support operational goals, they stop feeling like a burden. Well-managed racking helps:

• Increase throughput safely
  
• Reduce unplanned disruption
  
• Support growth and layout changes
  
• Maintain consistency across sites
  

That’s how warehouse racking regulation systems should work – not as a barrier to progress, but as quiet infrastructure that supports the business as it evolves.

Need help closing your warehouse racking compliance gaps?

Keeping your racking safe and fully compliant doesn’t have to be a headache, and having the right guidance makes all the difference.

BSE UK supports your team with rack safety awareness training, tailored to your warehouse and operations. In the training, learn how to identify risks, manage changes, and maintain safe racking systems across your site.

Email info@bse-uk.co.uk or call 0117 955 5211 to find out more. 

The post Warehouse Racking Regulations: The Hidden Compliance Gaps Most Sites Miss appeared first on BSE UK.

One of the top mistakes that are made in warehouse storage safety is choosing the wrong forklift for your racking system. This can majorly slow down your warehouse operations, can cause damage, and even put your teams at risk. Getting the right combination of racking and trucks is one thing, but ensuring your operators are trained correctly keeps things moving – all supporting your business growth.

Compatible Forklifts and Racking Systems

The type of racking system you choose will shape the way forklifts can move and operate around your warehouse layout, so picking the right truck is about understanding the layout and workflow on site, rather than the storage equipment alone.

Adjustable Pallet Racking

Adjustable pallet racking or ‘wide aisle’ racking is the most common type of warehouse storage solution. It’s modular design makes it useful for businesses needing a cost effective warehouse layout that allows flexibility for configurations and pallet sizes.

Counterbalance forklifts are the best match for this type of pallet racking. They move easily through standard width aisles and handle a variety of pallet sizes. For most warehouses that are scaling operations with conventional pallet racking, these trucks definitely balance cost and versatility with reliability.

Very Narrow Aisle (VNA) Systems

When your warehouse space is limited, (VNA) Very Narrow Aisle racking increases storage capacity without expanding the footprint. However, with this type of racking layout standard forklifts can’t navigate the narrow aisles safely due to their wider turning circles and movement at the end of aisles.

Articulated trucks – like Bendi, Flexi, or Aisle-Master models – are designed for tight spaces like a narrow aisle pallet racking system. They can move through narrow aisles, but also in open spaces, keeping stock flowing without slowing down operations or that need multiple truck types. With the added benefit of being an all-terrain truck, articulated forklift trucks are also able to operate in outdoor operations. Overall, these trucks have a higher up front cost, but offer high versatility to work effectively across mixed operations.

High Level Pallet Racking

High bays of pallet racking does exactly what it says on the tin, extending pallet storage at greater heights, but also comes with additional consideration when it comes to forklift requirements. Having staff work safely at height requires a truck designed to handle heavy pallet loads comfortably.

Reach trucks provide the lift and control needed for higher stock locations whilst remaining stable in narrow aisles. For warehouses handling more stock and higher lifts, they reduce risk and enable teams to maintain a steady and efficient workflow.

Why Training Makes a Difference

Even the right forklifts aren’t always enough if operators aren’t confidently trained in how to use them. Accidents often happen in everyday tasks – a misjudged turn, a rushed load placement, or limited visibility in narrow aisles.

Alongside suitable rack protection and warehouse traffic systems, professional training teaches operators how different forklifts interact with racking systems. It helps them to recognise hazards and work safely in busy warehouse environments.

A partner like HL Training offers accredited forklift operator training, including counterbalance, reach truck, and VNA courses. They provide both on-site sessions and training at their centre. With their range of courses that are industry- recognised by ITSSAR, RTITB, and AITT, forklift operators can gain skills that fully meet industry expectations.

Forklift training isn’t just a task to tick off the list. Your operators learn to navigate aisles safely, handle high capacity loads, understand safety protocols when using industrial trucks, and spot the early signs of rack damage. Flexible schedules make it easier to train your team without disrupting your daily operations.

The result is smoother operations, fewer accidents, and greater confidence on the warehouse floor.

Practical Tips for Safer Pallet Racking Operations

Beyond matching forklifts to racking and providing training, there are small practical  measures that make a big difference:

• Regular rack inspections: Carry out weekly routine checks where you should look for bent beams, ensure beam deflection is not beyond the rack manufacturers guidance, loose bolts, damaged floor fixings and damaged or dangerously loaded pallets – before they become costly hazards. Ensure you have a SEMA Approved Rack Inspector carry out an annual inspection in line with SEMA guidelines.
• Clear aisle management: Keep aisles free from obstructions such as pallets, equipment, packaging materials and waste, to reduce collisions, improve visibility, and ensures safe, efficient movement of goods and personnel. Maintaining aisles also supports compliance with health and safety regulations and ensures smoother warehouse operations.
• Safe Pallet Racking Loads: Ensure sure pallets don’t exceed rated capacity and are evenly stacked. They must be in good working condition, and be a size that suits your forklift trucks. All pallet racking bays must have weight loading signs signalling the maximum load per bay, and be clearly displayed at the end of each run of racking. Further information on safe weight limits can be found in our useful guide.
• Warehouse Traffic Signage and Floor Markings: Using visual markers, floor signs, and safety signage to communicate traffic rules helps forklift operators and pedestrians navigate safely. This is especially important in very narrow aisle (VNA) systems where space is limited and clear direction is essential. Clear signage improves warehouse safety, reduces accidents, and enhances operational efficiency.
• Forklift Maintenance Schedules: Regular maintenance and inspections warehouse trucks ensures they remain in safe working condition, reducing the risk of unexpected breakdowns, collisions, or workplace accidents. A consistent maintenance schedule helps extend the life of forklifts, improves operational efficiency, and ensures compliance with safety standards across the warehouse.

These practices, combined with the right forklifts and operator training, create a warehouse that is both safer and more reliable.

Pallet Racking Mistakes to Avoid

Even the most experienced operators and warehouse managers can make mistakes that affect safety and efficiency. Being aware of these can prevent costly accidents and downtime:

1. Assuming basic training is enough: Many businesses provide only introductory forklift training. Without ongoing, accredited training that matches your racking types, operators may not understand high-level lifts, VNA operations, or how different trucks behave in your warehouse layout.
2. Neglecting racking inspections: Racks may look fine from the floor. Small bends or loose bolts often go unnoticed until a heavy load causes damage.
3. Overloading pallets or racks: Even minor overloads can destabilise a system over time, increasing risk to staff and stock.
4. Ignoring aisle clearance: Temporary storage or equipment blocking aisles can cause collisions, especially in narrow spaces where manoeuvring is tight.
5. Treating trucks and racking as separate concerns: Equipment, layout, and human operation are interconnected. A change in one area can impact the others.

Avoiding these mistakes starts with understanding your warehouse operations inside and out, training operators properly, and implementing processes that keep the space safe and functional.

Safer spaces, smarter growth.

Pallet racking safety is not one dimensional –  it involves matching forklifts to the space, training operators, and designing workflows that work in practice.

When trucks, racking, and people are fully aligned and working in sync, stock can move efficiently, teams can work safely, and your warehouse can support your business’s growth. By focusing on the right equipment, training, and practical measures, you create a space that works for your current set up, and scales safely for tomorrow.

How BSE UK can help

If you’re looking to improve your warehouse operations and ensure your racking is safe and efficient, BSE UK offers a free pallet racking site visit. Our team can assess your layout, racking systems, and operational flow, and provide practical advice tailored to  your business. Call our friendly team on 0117 955 5211 or email info@bse-uk.co.uk.

The post Pallet Racking Safety: Choosing The Right Forklift For Your Warehouse appeared first on BSE UK.

Why Regular Rack Safety Inspections Are Essential

Warehouse racking takes a lot of daily wear and tear. Forklifts, pallets, and routine loading can cause damage that isn’t always immediately obvious. That’s why inspections should happen at different frequencies, with each serving a specific purpose:

• Ad-hoc checks - immediately after any impact or incident that may have damaged the racking. Quick visual checks catch urgent issues before they become serious. All users are responsible for reporting incidents and damage.
• Weekly visual checks – a routine walk-through to spot early signs of wear, leaning, dents, or missing components, recording findings on a structured check list to prevent minor issues from escalating. This is carried out by a Person Responsible for Racking Safety (PRRS).
• Annual inspections – a full, detailed assessment by a trained professional, such as a SARI inspector or qualified racking inspector, ensuring the racking meets safety standards and is fully compliant.

Legal requirements and compliance

In the UK, employers have a legal requirement under the Provision and Use of Work Equipment Regulations (PUWER) and the Health and Safety at Work Act 1974 to ensure storage equipment is safe and maintained for operation.
Following SEMA’s racking regulations and HSE guidance HSG76 helps demonstrate compliance with safety standards and good practice.

Health and safety responsibility

Beyond compliance, regular inspections are vital for maintaining a safe workplace and avoiding rack collapse - one of the most dangerous incidents in a warehouse environment.

A small but serious statistic

According to industry estimates, nearly 40% of warehouse accidents involve storage equipment. The vast majority could have been prevented through routine inspection, rack protection, and proper rack safety training.

For professional inspections or annual rack inspection services, see BSE UK’s racking inspection service.

Using the Green/Amber/Red Checklist System

The SEMA traffic light system helps warehouse operation managers prioritise repairs and maintenance quickly and clearly.

• Green: No or minor cosmetic damage – racking is safe to use, but should be monitored.
• Amber: Needs attention soon – isolate the bay of racking and repair before it worsens and causes an accident.
• Red: Serious damage - unload immediately and arrange rack repair or replacement with a credible supplier.

This system ensures that issues aren’t overlooked, helping you keep your pallet rack safety under control.

The post Rack Safety Inspection Checklist: Green/Amber/Red Criteria Guide For Warehouse Racking Safety appeared first on BSE UK.

When a pallet racking system collapses, it can cause hundreds and thousands of pounds worth of damage to stock, temporarily bring business to a halt and pose a credible threat of serious injury to anybody present at the time of collapse.

In most cases, pallet rack collapses are entirely preventable and happen as a result of bad practice, poor quality or unmaintained racking and improper training.

In this blog post, we take a look at the risks associated with a racking collapse, what causes a racking system to collapse and the measures that can be put in place to prevent it from happening.

Understanding the Risks of Pallet Racking Collapses

As well as the immediate risk to life, pallet racking collapses pose a number of risks to businesses and operatives including:

• Injury – As well as severe injuries, pallet racking collapses have resulted in death before.
• Fines – Under PUWER (Provision of Work Equipment Regulations), failure to keep working equipment (including pallet racking) in safe and working order can result in large fines and even prosecution from HSE.
• Destruction of Stock – Stock will almost certainly be damaged if not completely destroyed as a result of racking collapse.
• Downtime – In addition to the time taken to clear the debris and begin the cleanup operation, HSE may launch an investigation into the origins of the collapse should it see fit, resulting in even more downtime.
• Loss of Business – If customers orders cannot be fulfilled, contracts may be lost and the company’s reputation will be negatively impacted.

Preventing the Causes of Racking Collapse

Take a look at some of the most common reasons why racking systems collapse as well as tips for prevention which will cost a fraction in comparison to a collapse.

Failure to Maintain Pallet Racking

As well as increasing the risk of collapsing on its own, damaged or poorly maintained racking increases the risk of collapse when coupled with other causes such as forklift collisions or overloading. In order to keep your racking in its best condition:

• Carry out routine visual inspections for any damage. Download our free rack inspection checklist sheet which highlights where you need to check for faults.
• Have a full inspection carried out annually or if you notice damage to your system. For the greatest peace of mind, choose a SEMA approved racking inspector who will provide you with a full damage report.
• Ensure that any damage to warehouse racking is reported immediately. Avoid using the pallet racking until it is repaired.
• Operate and maintain pallet racking in line with manufacturer guidelines.

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Forklift Collisions

Collision with forklifts is one of the most common causes of racking collapse. In the video below, we see a forklift operative carrying a wide pallet through the warehouse, before clipping the column of a rack and causing an entire system to collapse.

In this case, it’s clear that the operative is driving too fast and carrying an unsuitable load for the narrow aisles. However, the system collapsing following such a small knock is an indication that the racks were overloaded or poorly maintained.

There are a number of methods that can be implemented to decrease the risk of a forklift collision and reduce the risk of collapse should one occur.

• Design systems with adequate space in between racks. As we saw in the video above, with a little more space, the racking collapse would’ve been avoided.
• Install rack protection including column guards, upright protectors and racking barriers to reduce the risk of collapse should a forklift collide with the system.
• Ensure driver’s receive proper training before operating forklifts.
• Ensure forklift safety practices are followed at all times by operatives.
• Implement speed limits for forklifts operating within the warehouse.
• Implement a clear floor marking system.
• Ensure the warehouse has adequate lighting.
• Ensure the correct type of forklift for the job is used.
• Keep aisles clear of any obstructions that will force forklift operatives to manoeuvre.

Overloading

When a racking system is overloaded beyond its limit, there is a chance that it could collapse. Additionally, overloaded racking systems are more prone to structural damage and more likely to collapse should they be struck by anything. To avoid overloading your racking:

• Know and abide by the manufacturer recommended weight limits, read our blog to find out more about calculating the weight limit of your pallet racking.
• Avoid buying second-hand pallet racking, this may have hidden damage and may not come with specific guidance around weight limits.
• Ensure that staff and forklift operatives are aware of the weight limits of the system when loading by displaying load notices at all times.
• Ensure that you are using the right type of racking for your stock. For example, long and bulky items are generally better stored in a cantilever racking system. Additionally, storing heavier loads in lower bays is good practice for reducing the risk of injury and improving efficiency.

Staff Negligence

Unfortunately, even with the best safety measures in place, a racking system collapse can still occur as a result of staff negligence. To reduce the risk of this:

• Consider rack safety awareness training to improve staff awareness of rack safety and the dangers associated with poorly maintained racking.
• Encourage staff to report any damage they may have caused to pallet racking.
• Increase supervision and management awareness to reduce incidents.
• Ensure staff do not climb on racking when picking.
• Train supervisory staff to pick up on any negligent behaviour that could lead to a collapse.

Poor Layout or Design

Poor layout or design of a pallet racking system can be its downfall. In the video below, you’ll see a forklift driver manoeuvring past a pile of stock in between two fully loaded pallet aisles.

After moving to avoid the stock in the centre of the aisle, he inadvertently gently knocks one of the columns, as a result, the entire racking system collapses causing a domino effect that takes down the majority of the warehouse.

In this instance, the layout of the aisles was at fault, with the obstruction in the middle leaving inadequate space for the forklift. Additionally, the fact that the system went down after such a small knock indicates that it was overloaded, improperly installed or poorly maintained.

The layout of a warehouse may become more dangerous as the operation grows, with new systems being added on and retrofitted without proper consideration. To prevent the risk of design or layout issues causing collapse, warehouse managers should ensure that any design or installation is carried out by a professional.

Incorrect installation

Incorrectly installed pallet racking is much more likely to become damaged or collapse. To prevent the risk of pallet racking being installed wrong:

• Use a professional accredited company who can install the system to the exact manufacturer specifications.
• For complete peace of mind, you should look for a SEIRS registered installation team who will install the racking in line with SEMA’s high standards.
• Never DIY anything when it comes to installing pallet racking.
• Always buy your pallet racking from a reputable manufacturer.
• Don’t try and integrate products from different manufacturers into the same system.

Further issues may arise when working with second-hand racking, so do take care when purchasing used stock.

Use of Bad Pallets

Not all pallets are suitable for use with pallet racking, particularly with drive-in racking systems. BS ISO 6780 2003 provides some useful information on this issue. Broken pallets can lead to beam failure due to irregular pressure placed on beam faces which may lead to a full collapse.

Racking Installation and Maintenance Experts

If you are responsible for the maintenance of pallet racking within your warehouse, you need to ensure your pallet racking system is well maintained, compliant with health and safety legislation and used properly in order to prevent a racking collapse.

At BSE UK, we provide a complete service for the installation, repair and ongoing maintenance of all pallet racking types from leading suppliers. For more information about how we could help you, give us a call today on 0117 955 5211, fill out a contact form or use the live chat to speak to one of our expert team now.

The post The Causes Of Pallet Racking Collapses and How To Prevent Them appeared first on BSE UK.

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Warehouse fires have been a hot topic of conversation recently, with a large fire devastating a warehouse on White Hart Lane and residents being evacuated in North West London following a huge blaze in the same month.

Fortunately, in both cases, the blazes were controlled (by a total of 190 firefighters!) without any injuries.Warehouse fires are devastating for business, not only destroying stock and causing long downtime but also putting employees at risk. To help ensure fire is not a risk in your warehouse, take a look at our 5 step fire safety checklist.

Don’t Overload Your Racking

Not only can overloaded pallet racking cause damage to your system, it can also pose a serious fire hazard. With more stock to burn through in a condensed space, overloaded pallet racking can be the difference between controlling a fire and letting it spread to the rest of your warehouse.

Ensure that you stick to racking weight limits and don’t overload – instead, find ways to maximise space in your warehouse, invest in racking that is designed to make the most of your space and consider a mezzanine flooring system to create extra storage space.

Train Your Staff

Proper training of staff is key to making sure procedure works. Staff need to be aware of fire risks and how to control them, consider these steps to ensuring this:

• Ensure all staff undertake at least a Level 1 Fire Safety course – this can be done online at any time. Designated fire marshals/wardens will be better equipped with a Level 2 Fire Safety award.
• Implement a fire procedure - ensure your staff know where fire equipment such as extinguishers are located as well as having a clear evacuation plan in place.
• Ensure smoking shelters are located away from any flammable materials – properly signpost designated smoking areas to avoid confusion and make sure there is a place to safely dispose of cigarette ends.
• Ensure employees are aware of the different materials they are handling, this will assist them in knowing which type of extinguisher to use in the event of a fire.
• Display racking weight limit notices on all racking.

Assess Your Inventory and Equipment

In both warehouse fire incidents during September, gas cylinders were on site. Whilst it is not noted where these were stored – the chances of them catching would have been significantly reduced if they were stored off-site in a gas cylinder cage.

Assessing your inventory will not only help you reduce the risk of fire, but also assist firefighters should there be one. Take note of any high-risk areas where flammable material is stored in abundance; it’s worth having a special fire prevention procedure and additional safeguards (sprinkler system, fire extinguishers and sensitive alarms) for these areas.

In addition to your inventory, ensuring your machinery is properly maintained is essential for staying compliant and preventing fires. For any moving machinery, a mesh machine guard or cage can prevent physical injuries as well as offering protection against welding flare.

Review Waste Removal Procedures

In 2016, a bin fire caused over $200,000 of damage to a warehouse in Toronto, how easy would this have been to prevent?

Having an abundance of rubbish stored in bins outside your site can make you a target for arsonists and vandals, follow these steps to ensuring rubbish doesn’t become a fire risk:

• Keep rubbish bins and skips stored in a cordoned off area away from your main buildings. You may choose to install security lighting in these areas.
• Keep them empty – reducing the amount of waste produced by your warehouse reduces the chances of a bin fire becoming unmanageable. Take a look at our latest blog to reduce waste in your warehouse.
• Ensure you use specialist services for any batteries and electronics that need disposing of.
• Try not to overfill bins and keep them securely shut.
• Clean your premises regularly to ensure rubbish doesn’t build up.

Conduct An End Of Day Inspection

Before you lock up for the night, carry out an end of day inspection to ensure there is nothing that could cause a fire in the night – ask yourself these questions:

1. Are the premises clear of any loose combustible materials?
2. Is waste awaiting in disposal in a secure, secluded space?
3. Are gas cylinders stored safely? (preferably away from the premises)
4. Are fire doors, exits, equipment and notices unobstructed?
5. Is every point of entry to the building and waste storage areas properly secured?
6. Are all electronics switched off, including machinery that is not in use?
7. Are all flammable liquids secured properly?

If your warehouse operates on a 24-hour basis, you may choose to carry out the end of day inspection between shift patterns.

Mezzanine Floor Fire Regulations

Not only do you need to pay attention to the general health and safety of your warehouse in terms of fire risk, but specifically to any mezzanine flooring too.

Mezzanine floors are generally immune to planning permission as long as any proposed changes are internal and each floor is less than 200m squared.

However, they will need to meeting building regulations and fire safety plays a big part in the construction and installation of mezzanine flooring. Building regulations necessitate that any elevated areas within a warehouse must possess an ambulant disable staircase which has specific requirements relating to tread, size of steps, landings and handrails.

In most cases simple storage only mezzanine floors do not require fire protection, but other uses will determine if the floor is required to be fire rated. So if it is considered a sufficient size to form an additional storey or is to be used as an office space, workroom or if people are generally working on the platform on a continuous basis, fire precautions will need to be taken.

Fire protection is a necessary and important part of building regulations and should be a priority in the planning stage when mezzanine flooring is being installed. This is usually included in the installation of a suspended ceiling installed below the mezzanine where fire rated tiles (at least rated 1 hour) are used.

Additionally fascia will be applied to expose edges of the mezzanine. It is also highly likely that a mezzanine is supported by columns, therefore it is also necessary that these are adequately protected against fire in order to comply. For example intumescent or fire retardant pant or PVC cladding with a one hour fire rating applied.

Talk To The Experts

What other measures do you have in place to prevent fires in your warehouse? We’d love to hear them. Don’t let it be a lack of space become a risk in your warehouse, give us a call on 0117 955 5211 to talk to one of our experts about space saving racking solutions and mezzanine flooring.

The post Fire Safety In The Warehouse: 5 Step Checklist appeared first on BSE UK.

A frequent issue that commonly arises in the warehouse is old, unsuitable or simply broken warehouse racking systems.

Not only is this insufficient for keeping up productive workflow and much needed organisation, but it poses a huge health and safety risk to all those in the workplace.

Whilst pallet racking is a particularly durable and reliable system with the correct installation and proper maintenance there can be a number of hidden dangers which can go unnoticed. It is therefore essential that you recognise the signs that your racking needs replacing.

Read more below:

Dangers of faulty Pallet racking

Regular inspection of your pallet racking is a legal requirement under UK law that requires an outside examination to be undertaken annually. At BSE UK we recommend an Annual Pallet Racking Health Check to ensure that all of your health and safety regulations are met.

However, don’t be fooled into foregoing your own regular inspection and maintenance. You’ll only end up with higher repair costs and the increased risk of potential damage to both your inventory and your staff.

1. Racking Repairs

General maintenance is healthy for your racking system, but constant fixes are a red light that you should be thinking of more long term solutions.

Whether an issue of overloading, wear or tear, or something worse, constant repairs are putting your employees in danger or risk of injury. Whilst you might consider yourself quite the “DIY’er” or even employ a fully qualified maintenance person a system consisting of a host of repairs is not a solid and acceptable solution.

A constantly faulty racking system can be a sign of a larger underlying problem such as bad design or overloading. Not only are your workers at danger of injuring themselves, but your racking and the stock placed on them are at risk of collapsing.

Another danger factor to making too many repairs is that your repairs themselves may be faulty. Instead the safest bet is to invest in some new racking suitable for the job which will not only save you the effort, but the time and money also.

2. Beam Deflection

Naturally, your beams will slightly deflect under a heavy load, however this should disappear as soon as your take the load off. If the beam stays deflected after removing the stock, then it is damaged.

Reloading your racking system with more stock after seeing this is then continuing to put your racking system in danger of collapsing and your workers in a hazardous position due to the risk of falling stock. Weight limits should be obeyed and the load should be supported by enough arms to prevent deflection.

If you notice a deflection in your pallet racking, you need to get a new beam or invest in a more appropriate racking system that can hold the mass of what you are storing.

3. Rust and Corrosion

Checking for rust and corrosion on your warehouse racking should be a standard job during your pallet inspection. Note any area’s with flaking paint, tarnished beams or corrosion as this is an indicator of the metal weakening.

For obvious reasons, your racking should not be weakened by rust. Even if you are abiding by the weight allowance of the racking, the frames will not be able to hold the original amount of weight if the metal is weakened. The mass of your storage may be too much for the weakened racking which could result in a collapse.

Unfortunately, there is no way to fix this and ignoring it is not going to make the situation any better. In such a case, Pallet Racking replacement is the most sensible solution.

4. Racking Protection

There is no way to fully protect your racking against inevitable damage and faulty components, but you can make sure this is less likely to happen with rack protection for warehouses.

Prevent your racking from damage against forklift damage with added security including column guards, up right protectors and racking barriers.

• Tubular Barriers offer strong protection at the ends of pallet racking to not only protect against vehicle damage, but are also perfect for creating separate stores areas and limiting vehicle access.
• Dexion Corner Guards can wrap around the pallet racking to protect against any kind of collision damage on the corner uprights. These also come with fixing bolts to make sure it won’t be moving anywhere.

Safety Guidelines

At BSE UK, we repair all damages to SEMA (Storage Equipment Manufacturers Association) guidelines which has been set as national and European standard for storage equipment.

You must be using these tips along with other guidelines to make sure your installation of racking, shelving and other forms of storage cohere to the guidelines.

Need Some Expert Help?

Whether you’re giving your pallet a full inspection, or you’re noticing as and when it happens, faults with racking should not be ignored. Make sure you’re regularly taking care of your warehouse and the contents within it.

With over 50 years of experience with pallet racking, we are here to help you in any way we can. If you need helping finding what’s best for your warehouse or want to find some racking that you can rely on, give us a call on 0117 955 5211 to speak to a member of our team.

Contact us

0117 955 5211BSE UK
Unit 2, Severnlink Distribution Centre,
Chepstow, NP16 6UN

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The post Signs that your racking needs replacing appeared first on BSE UK.

Fork Lift Safety in the Warehouse

We have said it time and time again, and we’re about to say it again. We cannot stress enough the importance of health and safety in the workplace. From correct moving and handling practices to proper signage there are a host of responsibilities you have as an employer.

And, although we haven’t previously covered it in great detail, fork lift driving is a major factor.

Whilst our Facebook page is all fun and games with our #FridayFail, which often features dangerous near misses with warehouse fork lifts, the potential for harm is very real. Have a read below as we discuss what provisions you need to put in place to ensure the safety of your employees.

General Forklift Practices

The powered industrial truck is used to lift and move materials short distance and is therefore ideal for use in the warehouse and similar environments.

However, forklifts can be particularly dangerous in the warehouse. In fact, on average they are forklifts are involved in a quarter of all workplace transport accidents which is on the whole largely due to insufficient training on forklifts for employees.

Fork Lift Training

According to the Health and Safety Executive forklift training should always include three stages as detailed below:

• Basic Training: Employees should be equipped with the basic skills and knowledge required to operate a lift truck safely as well as efficiently.
• Specific Job Training: Drivers should be provided with the knowledge and understanding of the operating principles and controls of the lift truck and how these will be used within their specific working environment.
• Familiarisation Training: Employees should be given the opportunity to apply what they have learnt under the normal working conditions of their new employment.

There is no specific requirement detailing the length of training as there are many issues that will affect the rate of an individual’s learning. Simply, training should be as long as it takes to meet all of the requirements.

In addition, it is important that even those who have received previous training, and therefore considered experienced, are routinely monitored in the workplace and when necessary tested or required to undergo refresher forklift training.

Basic Rules and Top Tips

We have compiled a handful of fork lift safety rules, as well as some excellent tips, to ensure that both employer and employee, as well as additional warehouse employees, are not put in a position of danger.

• Qualifications – As mentioned above, and perhaps the most important aspect of fork lift safety is ensuring that ALL future employees receive the proper and adequate training. Without these measures you will putting all employees at serious risk.
• Clothing – Appropriate clothing including safety work wear such as hard hats, safety shoes, and hi-visibility jackets should be worn at all times. In addition, all clothing needs to be reasonably fitted to avoid the risk of any loose clothing being caught in the machinery.
• Routine Checks – Just as you should be carrying out routine checks on your Pallet Racking, you should take the time to carefully examine the equipment on a daily basis. Ensure that you check for any faults, particularly focusing on the brakes, steering, controls, warning devices, masts, and tyres.
• The Environment – The driver should always pay attention to and carefully follow any site rules and guidelines. It is therefore your duty, as an employer, to ensure that the correct signage is in place and clearly visible to all employees. The operator must only drive the equipment in the machinery’s designated roadways to avoid collision and ensure that all signs are observed; especially those that lay out the rules for loadings and clearance heights.
• Don’t Speed – We’d hope that this one was a given but we’re including it anyway. Just as you should obey The Highway Code, drivers of fork lift trucks should never exceed the instructed speed limit. Corners and turns should be taken slowly to avoid tipping and coming to a stop should be gradual and slow.
• Avoid Hazards – We understand that this one is often easier said than done, but drivers should try and steer clear of any bumps, uneven ground surfaces, and slippery conditions. We’d suggest making use of the horn when closing in on a corner or doorway to alert pedestrians and other drivers of your presence to avoid unnecessary collisions.
• Never Overload – Ensure that you and your drivers know the capacity of the vehicle as well as any attachments and never exceed these. An overload can cause rear tyres to raise off the ground and could cause the truck to tip over.
• Clear Visibility – Never operate the truck if visibility is poor. Carry a load low to the floor to allow for improved forward visibility or alternatively choose to reverse. When stacking, ensure that you have a good view of the rack or top stack where a load should be positioned. However, we understand that poor visibility is inevitable; in this case we suggest that you employ a lookout or helper to ensure that no individuals are put at risk.
• Correct Equipment Use – Do not let other people ride on the equipment unless a second seat is fitted as the vehicles are designed to carry loads and not additional bodies.

More Help and Information

Whether you need a bit of advice regarding your warehouse operations, or are in need of updating or additional pallet racking give our team a call. Just dial 01179 555 211 and our knowledgeable and friendly team will be happy to lend you a hand.

Alternatively, why not check out our blog? We offer some great advice regarding all areas of warehousing which could help you ensure smooth, safe operations.

Contact us

0117 955 5211BSE UK
Unit 2, Severnlink Distribution Centre,
Chepstow, NP16 6UN

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The post Top Tips for Forklift Safety in the Warehouse appeared first on BSE UK.