Answer: If your pallet racking fails an inspection with damage identified, the damage gets identified, the severity gets ranked, and then you need to repair, replace or rectify whatever has been flagged. Some things can be monitored, some need fixing soon, and some need immediate action. The main thing is to deal with it properly and get the racking back up to standard.

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When it comes to warehouse racking inspections, a lot of businesses are really just trying to get a straight answer on what they need to do, how often it needs to be done, and what happens if something is not up to standard. To help break that down properly, we spoke with Shayne Grissell, Senior Rack Inspector at Macrack. Shayne has been with Macrack since 2005 and brings 21 years of hands-on experience across racking inspections, damage assessment, repairs, and compliance. In this interview, he talks through what a failed inspection actually means, the kinds of issues that get picked up, and what businesses need to do next to get their racking back up to standard. 

What happens if your racking fails an inspection?

Basically, it comes down to what has actually been found and how serious it is. Some things are more of a monitor ongoing situation, some should be fixed as soon as possible, and some are critical where the rack should be unloaded straight away and the damaged parts replaced.

Does failing an inspection mean the whole warehouse is shut down?

No, not necessarily. A lot of the time it might just be certain areas or certain bays that have issues. It really depends on the damage and how it has been categorised. Not every failed item means everything stops, but if something is critical, then that part needs to be dealt with straight away.

How is the damage usually categorised?

There are generally three categories, green, orange and red. Green is more of a monitor it and keep an eye on it. Orange is something that should be fixed as soon as possible, but it is not critical right that second. Red is critical damage. That means it needs to be replaced, and you should unload the rack straight away.

What sorts of things can cause racking to fail an inspection?

The main things we find are damaged uprights, damaged beams, and missing beam pins or locking pins. Another big one is when there are no safe workload signs on the rack. A lot of places we go to, there is literally no safe workload sign, so no one actually knows what they are meant to be putting on it.

Can missing safe workload signs really be that serious?

Definitely. If there is no safe workload sign, people are loading the rack without knowing what weight is meant to be going on there. That can be put down as a red because people are using the rack and do not know the limits.

What happens after the issues are found?

Once the inspection is done, the defects get written up in the report. Usually there will be a floor plan as well, so the customer can follow where the issues are and what needs to be looked at. It is basically a clear way of showing what is wrong and where it is in the warehouse.

What happens after you get the report?

Generally, the next step is to get the repairs sorted. That might mean getting a quote, booking the repairs in, and replacing whatever has been flagged. Some people want to do the repairs themselves, and some just want it all handled for them. Either way, the issues need to be rectified properly.

Can a business repair failed racking themselves?

They can, yes, in some cases. But a lot of the time it is easier and better peace of mind to have the people who know the product and know the standards do it properly. If the customer does do it themselves, it still needs to be checked afterwards to make sure it has been repaired the way it should be.

Why do a lot of businesses just get the same company to inspect and repair it?

Because it is easier, really. You get the audit, the quote and the repairs all by the same person, and it just gives the customer a bit more peace of mind. It also gets done quicker, which matters if they have got a notice hanging over their head and need to clear it.

What do you get once the repairs are done?

Once the repairs are finished and everything has been signed off, a compliance letter can be issued saying the pallet racking has been repaired and audited as of that date. That way, if anyone walks in and asks, the business has something on record showing it has been dealt with.

What happens if failed racking is ignored?

That is where it can become a serious problem. If the racking is too far gone, there is the possibility of failure, stock damage, or someone getting hurt. It can end up being catastrophic if it is left and people just keep using it.

Can delaying inspections make a failed result worse?

Definitely. If you stay on top of inspections every 12 months, you have probably got less damage to fix each year. If you leave it three or four years, by the time you get around to it, you could be looking at a much bigger repair job and a lot more disruption in the warehouse.

Do businesses usually act once they know the racking has failed?

Yeah, most do. Once they know there is an issue, they generally get it done and move on. Especially if they have been told they need to get it sorted, most businesses will do the right thing and get the audit and repairs done properly.

Bring Your Warehouse Back Up To Standard Today With Macrack

If your warehouse racking needs to be inspected, repaired, or brought back up to standard, contact Macrack today. Our team can inspect all major brands of racking, identify damage and compliance issues, help organise repairs, and keep your annual inspections up to date so problems do not turn into bigger risks later on.