A question that employers and businesses may ask themselves if they are looking for a racking system is, will a second-hand racking system suit our needs as well as our pocket?
To our mind, the answer is likely no, because of what may be unknowable, about what is being bought.
Key things to consider
- Where was it previously used and how?
- Was it properly maintained and if necessary, repaired?
- How was it dismantled, handled and stored in-between times?
If the answers to any of these questions are unknown, then it cannot be knowable that the structure will be safe to use. Relying on “It looked OK when we bought it” will not be sufficient as a fall-back position if the racking fails under load and injures someone.
Who designed and supplied the racking?
When originally designed, the specification was likely accurate and appropriate for its intended use, at that time. It likely met SEMA (Storage Equipment Manufacturers Association) design codes or the EU standard BS EN 15512, (used to check that the structure was suitable for the weight and type of stock that would be loaded onto it).
Additionally, the Health and Safety at Work Act and the Provision and Use of Work Equipment Regulations (PUWER) place legal duties on employers to ensure safe working practices and regular inspections of racking systems. SEMA also provides best practice guidance.
This is “the rub”, because whilst new storage systems need to meet these design codes / standards, it is not mandatory to redesign second-hand racking to these standards. This creates two problems:
- If the original company didn’t meet the requirements of the Design Codes it could have caused unnecessary wear and tear, meaning the racking being purchased second hand could be compromised
- There are no real assurances that the company supplying the second-hand racking is interested in providing equipment to the highest levels of quality and safety
One final consideration is the “load notice”. Correctly loading a racking system is essential to prevent workplace accidents and reduce the risk of it collapsing. New racking comes with a load notice attached to the structure, which clearly states the maximum load and any required load configurations for the bays themselves.
Is the supplier providing the racking with this essential safety signage and, more importantly, is the information correct?
Installation
To guarantee the long-term safety and performance of a racking’s structure it must be installed properly. To this end, an installer’s credentials must be in order. It is important to realise that many installers “learn on the job” and it is easy to pick up bad habits or, even worse, not know the correct methods in the first place.
If the original installer hasn’t followed the racking designer’s specification or missed crucial elements during installation it could result in unnecessary stress on the structure.
Maintenance
Racking safety requires a systematic approach. Ensure the person responsible for racking safety can recognise issues as they arise, via regular recorded inspections, the collation of damage reports, and the organising of regular maintenance to conduct remedial actions. A racking inspection regimen may look like:
- A daily ongoing check by employees – who address the racking, usually with a forklift – and who can identify obvious concerns as they arise and report them via a robust incident reporting system
- A monthly recorded check by the management which looks for damage and other issues (missing pins, bowing of beams, twisting or other damage to struts, crossbars or uprights, etc.) and that the loading within the bays is correct
- An annual inspection by a qualified inspector such as a SEMA approved racking inspector who will conduct an inspection and provide evidence of having done so
Using racking from new gives traceability of inspections from the start, whereas buying second hand may not do so. Even if the racking is only a couple of years old, that is a lot of checks to go through. Can the following be stated with confidence?
- Have inspections been conducted at all, and if so, to a standard and by a person with the correct competences?
- Do recorded inspections (the service record) cover the life of the racking?
- Were annual inspections conducted by a competent person (A SEMA approved racking inspector)?
- Do records indicate the depth of the inspection (Is it a damage only report)?
Racking repairs
Inspections are only worth the paper they’re written on if correct repair actions were followed. The knowledge gatherable about a second-hand structure will likely not prove whether the work was approved by the manufacturer or met industry standards.
An example if this would be “SEMA Technical Bulletin No. 09” which warns against cutting down and rewelding beams on racking, yet this is a common practice. Also, where it cannot be confirmed whether repairs were made correctly or not, purchasing the structure will come with an element of risk.
Structural integrity
The metal of the racking should last a lifetime, but it can be weakened. Has any rust occurred? If it has been under a warehouse roof, it should have been protected from the elements, meaning less risk of internal rust. But is this a certainty?
Also, consider what may have happened when the racking was dismantled. Not all racking is manufactured for outside use but it is not an uncommon occurrence for a company to store racking outside until it’s sold on. Has any extended exposure to external elements caused any damage or corrosion that has weakened the steel.
So, is second hand really a cost-effective solution?
Providing a cheaper solution by buying what might be damaged and therefore unsafe racking is not protecting the workforce and should not be what incentivises business managers. The upfront costs may be undoubtedly less than the alternative, but ongoing costs could very quickly outweigh the initial savings.
A second-hand system may be of unknown age, with no records of checks and maintenance and how it was used and the wear and tear the racking has encountered, which can mean that more frequent repairs, which can very quickly reduce its apparent cost-effectiveness. Then there’s the issue of who made the racking in the first place, if an approved replacement part is needed where will be it sourced, especially if the range has been discontinued?
Where a reputable manufacturer will likely provide ongoing support with compatible second-hand parts there are no guarantees with other suppliers and it could be that the “cheaper option” becomes a wasted investment, especially if the racking needs replacing again.
So, our advice is do not be incentivised by second hand prices. Whilst second-hand racking might deliver an upfront bargain, the lack of traceability, the cost of ongoing repairs and a reduced lifespan can quickly outweigh any short-term cost savings.
The use of racking systems should be the subject of a management process which includes the risk assessment process, explained within the associated guidance document “Storage Systems – Adjustable Pallet Racking”, as well as the associated document “Storage Systems – Adjustable Pallet Racking Checklist”, which allows for documentation of due diligence as it is undertaken. Both of these can be found on our Client H&S Portal.
To avoid accidents, causing harm and facing prosecution, ensure your business complies with health and safety law in 2025, by:
- Conducting risk assessments as and when required (prior to undertaking activities).
- Providing training regarding the risks involved and how to manage them.
- Supervising risk management, as necessary, until competence is demonstrated.
- Formally reviewing risk assessments and associated safe systems of work, regularly.
- Updating training provided (toolbox talks, in-house or external formal training).
- Keeping / updating records of all the above processes.
If you need any assistance with this or another H&S query, please do not hesitate to get in touch.