Safe, well-maintained storage equipment is essential for any warehouse operation. In the UK, one of the most recognised frameworks for professional racking assessment is the SARI Racking Inspection system. SARI refers to Storage Equipment Manufacturers’ Association (SEMA) Registered Inspectors, a network of accredited specialists trained to assess the condition of pallet racking and other adjustable static steel storage systems. Their inspections help warehouse managers understand the condition of their equipment, identify damage and prioritise corrective action.
This guide explains what SARI inspections cover, how they’re carried out, what the reporting process looks like and why the SEMA colour-coded risk system is central to ongoing warehouse safety.
What SARI Means in Practice
A SEMA Approved Racking Inspector is an independent professional trained to evaluate the structural condition of racking systems. Their role is to provide a thorough, impartial assessment based on SEMA’s technical guidance and recognised industry standards. The SARI programme is widely used across the UK because it offers a structured, consistent approach to identifying risks that warehouse teams may overlook during day-to-day operations.
Most warehouses combine internal weekly checks with an annual or biannual SARI Racking Inspection to maintain a clear picture of equipment condition and any developing issues.
What a SARI Inspection Covers
A SARI assessment looks at the entire storage system, including:
- Uprights, frames and base plates
- Beams, connectors and locking mechanisms
- Bracing and footplates
- Load notices and equipment identification
- Signs of impact damage
- Overloading or incorrect beam adjustments
- Floor condition around racking
- Visible corrosion or metal fatigue
- Alignment issues such as leaning or twists
- Accessories including anti-collapse mesh, barriers or guide rails
Inspectors physically examine components, check measurements against safe tolerances and review how racking is being used relative to the manufacturer’s load data.
How SARI Inspections Are Conducted
A typical SARI Racking Inspection follows a structured sequence.
1. Pre-inspection briefing
The inspector meets the warehouse manager to understand the site layout, traffic flow, lift-truck types and any recent incidents or changes to the storage system.
2. System walk-through
The inspector systematically walks each aisle, examining every bay. They use a combination of visual checks, measurement tools and manufacturer specifications to assess frame alignment, beam deflection and impact damage.
3. Verification of configuration
Racking adjustments sometimes invalidate original load capacities. The inspector checks beam heights, pallet spacing and accessories to ensure the setup still follows the intended design.
4. Impact and distortion checks
Even minor forklift strikes can cause twisting, dents or buckling. The inspector measures deflection within upright and beam tolerances to determine whether components require monitoring or replacement.
5. Documentation review
Load notices, rack identification and relevant technical details are checked for accuracy and visibility.
6. Final report and debrief
At the end of the visit, the inspector provides a clear explanation of findings, often highlighting immediate risks before issuing a formal written report.
The Colour-Coded Risk Categories
One of the most important outcomes of a SARI inspection is the colour-coded risk assessment. This system is used throughout the UK to prioritise actions and ensure warehouse managers understand which issues need attention.
Green Risk
No significant faults found. The racking is serviceable, though routine internal checks should continue. Green does not mean “no action ever,” only that no intervention is required at this stage.
Amber Risk
Damage is present but not severe enough to demand immediate off-load. The affected area must be monitored and rectified within a reasonable timeframe. Managers normally schedule repairs and recheck the area regularly.
Red Risk
Serious damage that requires immediate action. The affected bay or aisle should be off-loaded and isolated until repairs are completed. Red risks often involve visible buckling, severe twists, damaged connectors or compromised structural integrity.
This traffic-light approach ensures consistent decision-making and helps maintain a safe working environment without ambiguity.
Reporting Standards and Follow-Up
The formal inspection report is detailed and site-specific. It typically includes:
- A full list of damaged components
- Colour-coded risk levels
- Photographs of affected areas
- Diagrams or rack identifiers
- Recommendations for repair or replacement
- Notes on system configuration or improvements
Warehouse managers use this document to plan maintenance, engage suppliers for spare parts and schedule future checks. Many sites also keep historical reports to track recurring issues or forklift hotspots.
Why SARI Inspections Matter for UK Warehouses
Although warehouses carry out their own internal checks, external inspections offer impartiality and technical depth. SARI inspectors follow a recognised competency pathway, ensuring consistent standards across the UK. Their assessments help prevent costly disruptions caused by racking collapses, avoidable damage or compromised pallet handling.
Regular inspections also support good operational planning. Issues like misaligned beams or inadequate protection barriers often affect efficiency, not just safety. Identifying these early helps improve flow and reduce equipment wear.
Practical Tips for Warehouse Managers
Warehouse teams can prepare for a SARI visit by:
- Ensuring aisles are accessible
- Making load notices visible
- Providing layout drawings if available
- Reporting any recent impacts or adjustments
- Keeping forklift travel paths clear
Internal weekly checks should continue, focusing on visible impact damage, loose locking pins and unplanned beam changes. SARI inspections complement these routines rather than replace them.
Conclusion
A structured approach to racking assessment is essential for warehouse performance and long-term equipment reliability. The SEMA Registered Inspector framework gives warehouse managers a clear, practical method for evaluating the condition of their storage systems. Through systematic checks, clear reporting and a colour-coded risk system, a SARI Racking Inspection helps maintain safe, efficient and predictable warehouse operations.
