How do I know when my racking needs repairs?

Racking damage risk levels help determine when pallet racking needs repairs and how urgently action is required. According to industry guidance, racking damage falls into three categories: RED, AMBER, and GREEN. Each level clearly shows the severity of the damage and the correct response.

By understanding these racking damage risk levels, businesses can act quickly, reduce risk, and maintain safe storage systems.

Understanding racking damage classification

The SEMA racking risk levels form part of the recognised industry code of practice and guide maintenance decisions during inspections. Inspectors use this classification to decide when repairs are necessary and how quickly teams should respond.

RED risk damage

Red risk damage indicates a critical safety issue and requires immediate action.
Teams must:

  • Offload the affected racking immediately
  • Isolate the area from use
  • Replace damaged components before reuse

AMBER risk damage

Amber risk damage highlights a hazardous condition that needs prompt attention.
In this case:

  • Damage does not require immediate offloading
  • However, once offloaded, teams must not reload the racking until repairs are complete
  • Repairs should take place within a defined timescale

GREEN risk damage

Green risk damage remains minor and safe at the time of inspection.
Therefore:

  • No immediate repair is required
  • Teams can continue using the racking as normal
  • Inspectors should monitor the area during future inspections

Together, this red amber green racking damage system helps teams prioritise repairs and prevent minor issues from escalating.

How inspections identify racking damage severity levels

Regular inspections play a key role in identifying racking damage severity levels. Trained inspectors actively assess impact damage, deformation, and wear. They then categorise issues using recognised racking inspection risk categories.

As a result, routine checks and formal inspections help to:

  • Identify damage early
  • Prioritise repairs correctly
  • Prevent unsafe racking from remaining in use

Guidance from the Storage Equipment Manufacturers’ Association supports this approach, alongside health and safety advice from the Health and Safety Executive.

When to take action

If an inspection identifies RED or AMBER damage, teams should arrange repairs without delay. Even GREEN level damage needs regular monitoring, as repeated impacts can quickly increase risk.

If you are unsure how to interpret a pallet racking damage assessment, professional advice can help ensure you take the correct action.

Learn more about our racking inspection and repair services or contact our team to arrange an assessment.