Pallet Racking Inspection East Midlands Gateway

Pallet Racking Inspections at East Midlands Gateway

SEGRO Logistics Park East Midlands Gateway is a 700-acre inland port at Junction 24/24A of the M1, featuring a 50-acre rail freight terminal and direct access to East Midlands Airport. Home to Amazon, Nestlé, XPO Logistics, Shop Direct, Games Workshop and DHL, the park represents the cutting edge of UK logistics infrastructure. Clear internal eaves heights routinely reach 18m to 21m, with floor slabs designed to Category 1 TR34 specifications for high-reach automated equipment and multi-shift 24/7 fulfilment models.

Rackstor UK Ltd provides SEMA-aligned, SARI-accredited racking inspections for the demanding automated and high-bay environments at East Midlands Gateway and the surrounding DE74 logistics corridor.

Automated Systems & Structural Tolerances

High-bay installations at EMG operate at the outer edge of structural tolerances, where minor deviations compound into severe operational failures. In an 18m-high VNA racking system, an upright out-of-plumb variance of just 10mm can cause turret truck mast collisions with top-level beam frames. In automated crane or shuttle systems, beam deflection limits are tightened to L/300 or L/400 to prevent MHE sensor misalignments or pallet binding during automated insertion and extraction cycles.

Ultra-tall rack runs must be top-tied across aisles to distribute lateral sway forces, or designed as self-supporting free-standing structures with enlarged heavy-duty baseplates secured by high-tensile chemical anchors into thick structural concrete slabs.

High-Level Inspection at 18m+

Standard ground-level visual audits are insufficient for 18m+ racking structures. Our SARI inspectors use MEWPs and scissor lifts to inspect upper frame nodes, diagonal bracing and top-beam clip connectors. Key priorities include:

Safety Pin Verification: Every beam-to-upright connector must be secured with a genuine manufacturer locking pin capable of resisting at least 1.5kN of vertical uplift force. In high-speed automated environments, lifting forks snagging beam undersides routinely dislodge beams if pins are missing.
Bracing Member Buckling: Diagonal and horizontal frame bracing members are vulnerable to damage during upper-level pallet placement. Bent bracing components exceeding SEMA straightness tolerances are flagged for immediate replacement.
AMR & Conveyor Interface Points: Where automated guided vehicles interface with rack pick stations, structural guards must prevent impact with frame legs. These high-risk transfer zones are inspected for hidden structural fatigue.
Out-of-Plumbness Measurement: Every upright is checked for verticality against the SEMA limit. Shimming requirements at baseplates are documented where deviations are found.

PUWER 1998 & Statutory Safety Governance

Racking systems used as working platforms or integrated with automated cranes must undergo documented periodic safety inspections under PUWER Regulation 6. Management must maintain a dedicated Racking Safety Maintenance Log available for immediate inspection by HSE authorities. Multi-tier picking structures require continuous edge protection under the Work at Height Regulations 2005, with handrails at minimum 1100mm, mid-rails and toe-boards at minimum 150mm.

Our written reports are produced to BS EN 15635 and the SEMA Code of Practice, giving you the dated, signed documentation that regulators and insurers require.