How to Inspect Racking Before Buying

Inspecting your pallet racking before you commit to buying is essential, not just for ensuring its condition is suitable for your needs but also for confirming the parts are compatible and that they meet safety standards.

In this article, we will explain how to inspect any potential racking you’re considering purchasing, including what to look for and how to assess whether a used system is safe and suitable for your warehouse. This will help you avoid safety risks and unsuitable purchases.

Why Pre-Purchase Pallet Racking Inspections Matter

A pre-purchase racking inspection will help you confirm whether your used pallet racking is safe, serviceable and suitable for your warehouse or storage space.

Any issues found after installation will likely have to be fixed, which will lead to downtime and extra costs, as well as potential compliance problems.

Some of the key risks you’ll be able to avoid through a thorough early inspection include:

• Hidden structural damage such as bent uprights or deformed beams
• Incorrect component mix that prevents safe load distribution
• Non-compliant systems that fail to meet SEMA design guidance
• Unexpected refurbishment costs for replacement parts or repairs

A short inspection carried out by a competent person will help confirm the racking’s long-term value.

What Should You Check When Inspecting Racking Before Buying?

When you’re considering buying a set of pallet racking or even a full warehouse fit-out using second-hand racking, be sure to use the checklist below to ensure you assess all the key areas.

Start by checking the frame’s condition, then inspect beams, connectors and accessories. Confirm the system’s history and ensure parts match the required specification.

1. Upright Frames and Bracing

Uprights carry the main vertical load for your pallet racking, making them incredibly important.

Any damage to your upright frames will reduce their strength and stability. This means the racking will be unable to support its rated load, posing a threat to your pallets, operators and equipment.

When inspecting your uprights and bracing, keep an eye out for:

• Bent or twisted uprights – Look for uprights that are no longer straight when viewed from the front or side, or that lean slightly compared to neighbouring frames
• Cracked welds – Check around connection points and bracing joints for hairline cracks, separation or even flaking paint
• Missing or loose bracing – Look for bracing sections that are detached or visibly loose (listen out for rattling also)
• Corrosion at the base plates – Inspect the base area for rust, bubbling paint or flaking metal, especially where the upright meets the floor
• Repairs or straightening marks – Assess uneven surfaces, grinding marks, heat discolouration or areas where the paint has been stripped and reapplied

Record the location and severity of any defects, as even minor dents can significantly reduce load capacity.

2. Beams and Connectors

Beams carry the pallet loads and transfer the weight into the uprights. Any distortion affects both strength and alignment.

When inspecting beams and connectors, look for:

• Beam deflection – Check for sagging or a visible dip along the beam length when unloaded
• Twisting or rotation – View beams from the end to spot torsion or twisting caused by overloading
• Damaged connector plates – Check the beam ends for cracks, warping or enlarged connector holes
• Missing or damaged locking pins – Confirm that safety clips or locking pins are present, secure and undamaged
• Wear marks – Look for scraped paint, deformation or metal shine around the connector area, which may indicate repeated impacts

Beams should sit level, lock securely into the uprights and show no signs of permanent deformation.

3. Base Plates and Floor Fixings

Base plates anchor each upright to the floor and help maintain system stability.

When inspecting floor fixings, look for:

• Missing fixings – Check that all bolt positions are filled and correctly aligned
• Loose fixings – Test bolts gently for movement or play
• Damaged plates – Look for bending, warping or distortion at the base
• Corrosion – Inspect for rust or pitting around the fixing points, especially in damp or chilled environments

Secure and intact fixings are essential for safe operation.

4. Base Plates and Floor Fixings

Used racking often includes a mix of parts from different systems. Mixed components may not be compatible and can reduce overall load capacity.

When verifying racking specification and compatibility, check for:

• Manufacturer labels or profiles – Look for stamped or printed identification
• Matching component profiles – Compare upright slot patterns and beam connector designs
• Consistent beam lengths and frame depths – Measure components to confirm a uniform configuration
• Original Safe Working Load (SWL) data – Confirm load ratings from the supplier or documentation
• Availability of replacement parts – Check whether parts are still manufactured or supported

Avoid systems with unverified or mismatched components.

5. Load Capacity and Previous Use

Understanding the system’s history helps you assess hidden wear.

When reviewing previous use, request:

• Inspection records – Check for recurring defects
• Load notices – Confirm original capacity
• Details of pallet weights – Note in particular whether loads were evenly distributed
• Information on forklift types – Be aware that heavy machinery increases impact risk
• Repair history – Identify frames or beams that have needed repeated work

Racking used for heavy or high-intensity operations may show accelerated wear.

6. Surface Condition, Corrosion and Coatings

Surface condition gives early clues about long-term structural integrity.

When checking coatings, look for:

• Surface rust – Spot early corrosion, especially around welds
• Chipped or flaking paint – Look for impact areas or abrasion points
• Chemical staining – Note any discolouration from oils, solvents or other residues
• Moisture marks – Common in cold stores or high-humidity sites

Light corrosion is manageable, but deep pitting suggests weakened steel.

7. Accessories and Safety Components

Accessories support safe operation and should be included or replaced if missing.

Check the condition of:

• Column guards – Look for crushed sections or repeated impact marks
• Rack end barriers – Check for bending or loose fixings
• Load notice signs – Ensure they are present and legible
• Pallet support bars – Check for bending or loose fixings
• Mesh or timber decking – Inspect for cracks, broken welds or sagging panels

Missing accessories increase installation cost and reduce safety.

How to Inspect Warehouse Racking in a Systematic Way

A structured process helps ensure you inspect every component in a consistent way. This reduces the chance of missing hidden defects.

Follow these steps:

1. Identify the racking type using labels or profiles.
2. Measure uprights, beams and frame depths to confirm specification.
3. Inspect upright frames from the base upward.
4. Check each beam level, including connectors and safety pins.
5. Review base plates, fixings and accessories.
6. Check for corrosion, coating damage or deformation.
7. Photograph defects for later comparison.
8. Request documentation to verify condition and capacity.

Inspect each run from left to right, then repeat on the opposite side to ensure both faces of the racking are checked.

Relevant Standards for Pallet Racking Inspections

Used racking should align with recognised safety guidance. These standards help you judge whether a system has been maintained correctly and whether any defects fall within acceptable limits.

The main standards to be aware of are:

• SEMA Codes of Practice – Provide detailed guidance on safe design, installation and inspection of pallet racking.
• EN 15635 – Sets out requirements for the application and maintenance of storage equipment, including damage limits and inspection procedures.
• PUWER regulations – Ensure equipment used at work is safe, suitable and maintained to a safe standard.

A competent person, ideally trained under the SEMA scheme, should assess any racking with visible damage or unclear specifications.

Their assessment helps you confirm whether the racking can be used safely once installed.

What Defects Make Racking Unsuitable for Purchase?

Some defects indicate the racking is unsafe or no longer performs to its original design.

These issues usually cannot be repaired cost-effectively or may not meet recognised standards after repair, and as such, purchasing them would be completely unadvisable.

Avoid buying pallet racking with:

• Uprights bent beyond SEMA green limits
• Cracked or distorted beam connectors
• Missing bracing affecting frame stability
• Corrosion causing metal loss or deep pitting
• Unknown manufacturer or unverified components
• Evidence of structural weld failure

If you cannot confirm the system’s specifications, treat it as non-compliant. Racking without verified load data or component compatibility should not be used.

How Often Does Your Racking Need to be Inspected Once Installed?

Once installed, racking must be checked regularly to maintain safety and meet EN 15635 requirements. Different types of inspections identify different issues at different stages.

Racking should be inspected:

• Weekly by a trained internal observer – Quick visual checks to spot new damage, misaligned beams or missing safety pins.
• Annually by a SEMA-qualified inspector – A detailed structural assessment that confirms long-term compliance and identifies defects that require repair.
• After any impact or suspected damage – Immediate inspection ensures the system remains safe before pallets are returned to the area.

Regular inspections help you identify damage early, reduce repair costs and maintain safe working conditions.

For more information on how racking survey intervals, have a read of our full-length article on the subject of how often pallet racking should be inspected.

Key Questions to Ask the Racking Supplier

Before buying, request clear information to support your decision, such as:

1. Has the racking been inspected by a competent person?
2. Are inspection reports available?
3. What is the manufacturer, model and load capacity?
4. Are all components original and compatible?
5. Are any repairs known or documented?
6. What accessories are included?

Supplier transparency is a strong indication of product quality.

Conclusion

Inspecting racking before buying helps you confirm it is safe, compatible with your warehouse layout and able to perform as expected. Check the condition of uprights, beams, connectors and accessories, and make sure the manufacturer and load data can be verified. Avoid systems showing structural damage or unverified components.

A clear, systematic inspection gives you confidence that the racking meets both operational and safety requirements. For professional advice on guidance on pallet racking, get in touch with our team at Pallet Racking Systems.