Annual Pallet Racking Safety Inspection — Envirowales Ltd, Ebbw Vale, South Wales
- Client
- Envirowales Ltd
- Location
- Plateau 1 & 2, Rassau Industrial Estate, Ebbw Vale, South Wales
- Inspection Date
- 23 June 2026
- Inspection Type
- Comprehensive Annual Pallet Racking Safety Inspection
Project Overview
Rackstor UK Ltd was commissioned to undertake a comprehensive statutory pallet racking safety inspection at Envirowales' busy industrial facility in Ebbw Vale. The warehouse operates a combination of adjustable pallet racking, longspan shelving and industrial shelving systems which are subjected to constant daily forklift activity. The inspection was completed in accordance with recognised industry guidance and legislation, identifying structural damage, operational hazards and compliance issues requiring corrective action.
The Challenge
Like many busy warehouses, years of continual forklift movements and operational demands had resulted in gradual deterioration of parts of the storage installation. During the inspection our engineers identified a combination of: forklift impact damage, missing safety components, installation defects, incorrect bracing configurations, missing load notices, progressive structural damage, and operational safety concerns. The report concluded that impact damage was chronic rather than isolated, indicating ongoing operational issues rather than a single incident.
What We Found
Damaged Uprights
Multiple pallet racking uprights had sustained forklift impact damage affecting the structural integrity of the frames.
Damaged Beams
Several load beams had suffered impact damage and permanent deformation which reduced their safe load carrying capacity.
Bent & Damaged Bracing
Frame bracing members had been struck and distorted, reducing frame rigidity and increasing the risk of instability.
Missing Beam Safety Locks
Numerous beam locking pins were either missing or incorrectly installed, significantly increasing the possibility of accidental beam dislodgement during loading operations.
Floor Anchor Issues
Some pallet racking frames were inadequately anchored to the warehouse floor, reducing overall structural stability.
Deflected Decking
Timber decking showed excessive deflection caused by loading patterns and long-term use.
Damaged Column Guards
Existing column guards had become ineffective due to repeated impacts and no longer offered adequate protection.
Compliance Issues
- Missing maximum safe load notices
- Non-standard frame configurations
- Previous modifications not matching manufacturer recommendations
- Areas requiring procedural improvements
All findings were fully documented with photographic evidence and prioritised according to risk level.
Our Recommendations
- Replacement of damaged uprights
- Replacement of damaged beams
- Replacement of damaged bracing members
- Installation of new beam locking pins
- Replacement and testing of floor anchors
- Installation of new column guards
- Supply and installation of compliant load notices
- Review of forklift operating procedures
- Improved aisle protection
- Staff awareness and warehouse safety recommendations
Standards Applied
- • BS EN 15635
- • PUWER
- • HSG76 Warehousing & Storage Guidance
The inspection also considered manufacturer guidance and accepted industry best practice when assessing the condition of the storage systems.
The Outcome
- Complete condition assessment
- Prioritised remedial schedule
- Photographic evidence of all significant defects
- Recommendations to improve warehouse safety
- Guidance to reduce future forklift damage
- Clear maintenance strategy for ongoing compliance
By identifying damage early, the client can now plan repairs before minor defects develop into major structural failures, helping to protect employees, stock and business continuity.
Why Regular Racking Inspections Matter
Even well-managed warehouses can develop damage over time. Forklift impacts, overloaded bays and missing safety components often go unnoticed during day-to-day operations. Regular independent inspections help businesses:
- Improve warehouse safety
- Reduce the risk of collapse
- Demonstrate legal compliance
- Protect employees
- Reduce costly downtime
- Extend the lifespan of storage systems
- Plan repairs before failures occur
Need a professional pallet racking inspection?
Rackstor UK Ltd carries out professional pallet racking safety inspections for warehouses throughout the UK.
Call 0800 654 6955