Industrial Racking & Shelving RAMS: SEMA Guidelines and Risk Assessment for Warehouse Racking Installation

Table of Contents

• Why Industrial Racking RAMS Matter
• SEMA Guidelines and Your Documentation Obligations
• Key Hazards in Racking Installation
• Working at Height During Racking Erection
• Anchor Bolt Installation and Floor Integrity
• What Your Racking RAMS Must Cover
• Frequently Asked Questions
• Next Steps

Why Industrial Racking RAMS Matter

Industrial pallet racking installation is a specialist trade with a safety record that has driven significant regulatory attention. Racking collapse — typically resulting from overloading, impact damage, or inadequate installation — can cause multiple fatalities and the destruction of warehouse contents worth millions of pounds. Principal contractors on warehouse and logistics projects apply close scrutiny to racking RAMS because of the post-installation life safety implications of deficient installation.

Under CDM 2015, racking installation contractors are duty holders who must produce a project-specific RAMS. The Provision and Use of Work Equipment Regulations 1998 (PUWER) also apply, as installed racking is work equipment whose suitability and structural integrity must be verified before use. The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER) may apply where racking is used with mechanical pallet handling equipment.

This guide explains what a compliant industrial racking RAMS must include, with particular focus on the SEMA design and inspection standards that underpin UK racking safety.

Browse all trade RAMS templates on the RAMS AI trade hub — covering 22 specialist construction trades.

SEMA Guidelines and Your Documentation Obligations

The Storage Equipment Manufacturers Association (SEMA) publishes codes of practice and guidelines that are the accepted industry standard for racking design, installation, and inspection in the UK:

• SEMA Code of Practice for the Design of Static Steel Pallet Racking — governs the structural design of pallet racking systems
• SEMA Guide to the Conduct of Pallet Racking and Shelving System Surveys — used by SEMA-approved inspectors conducting periodic inspections
• SEMA Recommendations for the Design and Use of Mobile Racking Systems — for mobile (moving aisle) racking systems

Your RAMS should reference the relevant SEMA codes and confirm that:

• The racking system has been designed in accordance with the applicable SEMA code by a competent structural engineer
• The design load (maximum pallet weight, bay UDL, floor loading) has been confirmed by the racking designer and verified against the structural floor specification
• The installation will be carried out by trained erectors in accordance with the manufacturer's installation instructions and the SEMA code
• A post-installation inspection will be carried out before the racking is commissioned for use

Key Hazards in Racking Installation

• Working at height — Racking systems in modern warehouses are frequently 7-15 m tall. Installation of upper beam levels and cross-bracing requires sustained working at height using MEWPs or mobile access towers.
• Racking instability during erection — Partially erected racking bays are structurally unstable until bracing and cross-ties are installed. Unbraced frames can topple during erection, particularly in outdoor environments with wind loading.
• Manual handling of heavy frame components — Racking uprights and frames are typically 2-10 m tall and weigh 30-100 kg per section. Manual handling risk assessment must address two-person lifts, the use of mechanical handling aids, and the management of frames in windy conditions.
• Concrete drilling for anchor bolts — Anchor bolts are chemically or mechanically fixed into the structural floor slab. Drilling generates silica dust and noise. Hitting buried services or post-tension tendons during drilling is a critical risk.
• Fork lift truck (FLT) operations — Racking installation frequently occurs in warehouses where FLTs are operating. FLT-pedestrian conflict is a leading cause of fatal accidents in warehouse environments.
• Component collapse during installation — Beams dropped during installation from height can cause fatal injuries to operatives below.

Working at Height During Racking Erection

Working at height is the primary hazard during installation of tall racking systems. Your RAMS must specify:

• MEWP selection — For racking installations above 3 m, scissor lifts or narrow aisle cherry pickers (designed to operate within the racking aisles) are the preferred access method. Specify the MEWP type, category, and IPAF certification requirement for operators.
• MEWP floor loading — Confirm that the warehouse floor slab can support the MEWP's point load. Post-tensioned or precast floors may have restrictions — obtain a written confirmation from the structural engineer or principal contractor before deploying MEWPs.
• Unstable frame prevention — During erection, specify the sequence for installing temporary bracing or props to stabilise partially erected bays before operatives work at height on adjacent sections. No operative should work at height on a racking structure that is not laterally stable.
• Dropped object prevention — Beams, bolts, and tools must not be left unsecured at height. Specify the use of tool lanyards for all hand tools used at height, and the prohibition on leaving beams resting on partially connected locations before bolts are properly torqued.

Anchor Bolt Installation and Floor Integrity

Anchor bolt installation is a critical safety step — inadequate anchorage is a leading cause of racking collapse under load. Your RAMS must specify:

• Pre-drilling checks — Before drilling any anchor bolt hole, confirm the location of post-tension cables (for post-tensioned slabs), embedded services, and any areas of reduced slab thickness or construction joints. Obtain structural drawings from the principal contractor.
• Drill bit specification — Specify the drill bit type, diameter, and depth for the specific anchor bolt and floor specification. Wrong diameter holes prevent the anchor bolt from achieving its rated pull-out strength.
• Silica dust controls — Drilling into concrete generates RCS. Specify on-tool dust extraction (M-class or H-class vacuum), RPE (FFP3 minimum), and noise protection for drilling operations.
• Anchor bolt torque specification — After installation, anchor bolts must be torqued to the manufacturer's specified torque using a calibrated torque wrench. Specify the torque value and record method (torque wrench calibration certificate and torque record sheet).
• Chemical anchor cure time — If resin anchors are used, specify the minimum cure time before any load is applied to the anchor.

What Your Racking RAMS Must Cover

• SEMA code reference and design load confirmation
• Floor loading verification: structural drawing obtained, MEWP and design load confirmed
• Working at height: MEWP type, IPAF requirements, floor loading confirmation
• Erection sequence: temporary bracing of unstable frames, no height work on unbraced structures
• Dropped object prevention: tool lanyards, beam connection rules
• Pre-drilling checks: post-tension cables, services, construction joints
• Anchor bolt installation: drill specification, silica dust controls, torque record
• FLT-pedestrian conflict: segregation of racking erection zone from FLT operations
• Manual handling: frame weight, two-person lift rules, mechanical aids
• Post-installation inspection: SEMA-approved inspector, inspection record
• CDM pre-start briefing record

Frequently Asked Questions

Who must carry out the post-installation inspection of industrial racking?

The post-installation inspection should be carried out by a SEMA-approved rack inspector or a similarly qualified person with appropriate structural knowledge of the racking system type. SEMA maintains a register of approved racking inspectors. The inspection must be completed and any deficiencies rectified before the racking is commissioned for use with pallets or other loads. The inspection record must be retained by the building owner as part of the racking's safety documentation.

What load label information must be attached to completed racking?

Every pallet racking installation in the UK must have a clearly visible load notice specifying the maximum safe uniformly distributed load (UDL) per bay, the maximum safe load per beam level, and the maximum load per pallet position. This information is determined by the racking designer and must be confirmed and displayed before the racking is put into use. The racking contractor is responsible for ensuring the load notice is installed as part of the installation handover.

Can we install racking while FLTs are operating in the same warehouse?

Only if effective segregation is in place between the racking installation zone and the FLT operating area. A physical barrier (Heras fencing, barriers, or cones with safety tape) must separate the two areas, and FLT operators must be briefed on the exclusion zone before racking work begins. The segregation must be maintained whenever operatives are working in the racking area, particularly during high-risk activities such as working at height or when erecting frames. In smaller warehouses, it may be necessary to suspend FLT operations entirely during high-risk phases of racking installation.

Next Steps

Your industrial racking RAMS should be reviewed for every project, as floor slab conditions, racking height, and FLT interface vary significantly between sites. RAMS AI generates comprehensive racking risk assessments pre-populated with the SEMA-aligned hazards and controls described in this guide.