Pallet Racking Safety Inspection — Gardner Denver UK Ltd, Bradford, West Yorkshire
- Client
- Gardner Denver UK Ltd
- Location
- Industrial manufacturing facility, Bradford, West Yorkshire
- Inspection Type
- Comprehensive Pallet Racking Safety Inspection
- Overall Fault Score
- 52.2 / 100 — Fair Condition
Project Overview
Rackstor UK Ltd completed a comprehensive pallet racking safety inspection at the Gardner Denver UK manufacturing facility in Bradford, West Yorkshire. The inspection covered a large Dexion Speedlock MKIII adjustable pallet racking installation operating within an ambient warehouse environment using counterbalance forklift trucks. It was undertaken as part of the client's statutory obligations for warehouse safety and storage equipment management.
Storage Equipment Inspected
- Dexion Speedlock MKIII Adjustable Pallet Racking
- Wide aisle pallet racking installation
- Timber pallet storage
- Counterbalance forklift operation
- Concrete floor installation
- Ambient warehouse environment
Inspection Objectives
The inspection was undertaken to determine whether the pallet racking remained safe for continued operation, while identifying:
- Structural damage
- Installation defects
- Missing safety components
- Operational risks
- Compliance issues
- Areas requiring immediate remedial action
Overall Condition
The installation was assessed as being in fair condition, with an overall fault score of 52.2 / 100. The majority of defects were considered correctable through planned repairs and improved warehouse operating procedures.
Key Findings
Historical Forklift Impact Damage
Repeated historical impacts had damaged upright posts, lower frame bracing and front load beams. This reduced the integrity of affected bays and required replacement of damaged components where necessary.
Missing Beam Locking Pins
Numerous beam locking devices were missing, incorrectly fitted or of the incorrect specification. Beam locks are essential in preventing accidental beam dislodgement, so replacement was a key recommendation.
Damaged Structural Bracing
Several frame bracing members had sustained impact damage. Bracing provides rigidity and prevents lateral movement, so damaged members should be replaced rather than repaired.
Beam Damage
Several load beams displayed damage consistent with forklift impact. Bent or damaged beams reduce load carrying capacity and transfer stress into adjoining uprights, so replacement was recommended.
Anti-Collapse Mesh Issues
Anti-collapse mesh had become dislodged, was incorrectly mounted or required re-housing. Evidence suggested pallets were being positioned too deeply, causing repeated contact with the mesh brackets.
Frame Orientation
Some frames were installed in an orientation differing from the manufacturer's recommended configuration. This did not immediately reduce load capacity, but correcting it during future repairs would improve long-term stability and compliance.
Missing Load Notices
Maximum Safe Working Load notices were absent. These are essential for operators to understand the safe operating limits of the installation.
Loose Floor Fixings
Several anchor fixings required tightening after evidence of movement from operational impacts. Routine monitoring was recommended.
Minor Corrosion
Some superficial corrosion was identified. This was not structurally significant at the time of inspection, and preventative maintenance was recommended.
Operational Recommendations
- Reviewing forklift operating procedures
- Improving pallet positioning accuracy
- Maintaining safe working clearances
- Installing additional column guards
- Installing end barriers
- Improving operator awareness
- Replacing damaged components using manufacturer-approved parts
- Ensuring future installations comply with manufacturer specifications
Why Regular Racking Inspections Matter
Many warehouse safety issues develop gradually over time. Without regular inspections, minor impact damage can develop into structural defects that compromise personnel safety and business continuity. Routine inspections allow defects to be identified before they become major safety risks — reducing downtime and helping businesses meet their statutory responsibilities.
The Result
The inspection identified structural damage requiring replacement, installation defects, missing safety components, procedural improvements and compliance recommendations. With the recommended remedial work completed, the warehouse can continue operating with significantly improved levels of safety, compliance and confidence.
Need a Pallet Racking Safety Inspection?
Rackstor UK Ltd carries out professional pallet racking inspections for warehouses, factories, distribution centres and logistics facilities throughout the UK. Regular inspections help you:
- Meet legal responsibilities
- Identify damaged racking before failures occur
- Improve warehouse safety
- Protect employees and stock
- Extend the lifespan of storage systems
- Reduce long-term repair costs