Need a Annual Racking Inspection by our SEMA Approved Racking Inspectors? Trust A-Z Rack Inspections Ltd - Call 07917 664940 or 07947 886161 today!!

From Red to Green: Understanding the Racking Inspection Traffic Light System

Introduction

In any warehouse, pallet racking systems form the backbone of daily operations, holding thousands of kilograms of stock, supporting fast-paced logistics, and withstanding constant movement from forklifts and other machinery. But with so much activity, even minor damage can escalate into serious safety risks if not properly identified and addressed. That’s where routine racking inspections and the traffic light classification system come in, offering a clear, consistent way to assess risk and take action before small issues become costly accidents.

At A-Z Rack Inspections Ltd, we use the SEMA traffic light classification system to assess damage levels and recommend appropriate action during our racking inspections. In this article, we explain what each colour means, how the system works, and what your next steps should be depending on the outcome.

What Is the Racking Inspection Traffic Light System?

The racking traffic light system is a standardised safety classification model used by SEMA Approved Racking Inspectors (SARIs). It provides a clear, visual way of categorising the severity of damage or risk found on pallet racking systems during inspections.

The colours, Red, Amber, and Green indicate the level of risk and urgency for remedial action:

• Red Risk – Immediate action required

• Amber Risk – Action required soon

• Green Risk – No immediate action, but monitor

This simple framework helps warehouse managers prioritise safety repairs and stay compliant with HSE regulations, PUWER 1998, and SEMA guidance.

Red Risk: Stop and Repair Immediately

A Red Risk classification means the damage poses a serious safety threat and could result in racking collapse or structural failure. In this case:

• The area must be unloaded immediately

• The damaged component must be repaired or replaced before reuse

• Access to the affected racking should be restricted until resolved

Examples of Red Risk Damage:

• Severely bent or twisted uprights

• Broken beams or connectors

• Damaged bracing

Ignoring red risk areas could result in a range of serious consequences so if a Red Risk is flagged, action must be taken without delay.

Amber Risk: Monitor and Schedule Repair

An Amber Risk indicates moderate damage that does not yet require immediate unloading, but should be repaired as soon as possible, ideally within four weeks. Continued use is permitted temporarily, but the damage should be closely monitored.

Examples of Amber Risk Damage:

• Slightly deformed uprights

• Damaged bracing

• Minor impact to baseplates

• Misaligned beams

Amber risks are warning signs. If ignored, these could escalate into red-level hazards, so regular visual checks and planned repairs are essential.

Green Risk: Safe, But Keep Monitoring

A Green Risk classification means the racking is in serviceable condition, with no safety concerns identified at the time of inspection. However:

• Continue routine visual inspections

• Maintain a preventative maintenance schedule

• Ensure operators remain trained and vigilant

Green doesn’t mean “forget about it”—all racking systems should still be checked regularly, especially in high-traffic or high-turnover environments.

Why the Traffic Light System Matters

✅ Clear & Actionable

The traffic light system gives warehouse managers simple, visual feedback that turns complex inspection results into clear actions.

✅ Prioritises Safety

By categorising damage severity, it ensures the most serious hazards are dealt with first—helping to prevent accidents and reduce liability.

✅ Supports Compliance

The system is aligned with HSE’s HSG76: Warehousing and Storage – A Guide to Health and Safety, which recommends annual inspections by a competent person, such as a SEMA Approved Racking Inspector.

How A-Z Rack Inspections Ltd Uses the Traffic Light System

When you book a racking inspection with A-Z Rack Inspections Ltd, we provide:

• A full visual inspection by a SEMA Approved Racking Inspector (SARI)

• A traffic light-coded damage report

• A risk assessment summary with detailed findings

• Remedial action recommendations

• Photographic evidence of defects

• Compliance guidance and advice

Our goal is to ensure your warehouse racking is safe, compliant, and built for long-term use.

Your Responsibilities Under PUWER and HSE Guidelines

The Provision and Use of Work Equipment Regulations (PUWER) 1998 requires employers to ensure that work equipment, including pallet racking is:

• Suitable for use

• Maintained in a safe condition

• Inspected regularly by a competent person

HSE guidance recommends annual expert inspections, supported by weekly internal checks. Using the traffic light system helps demonstrate that your business is following best practice and protects your team.

Don’t Wait Until It’s Too Late

Warehouse racking inspections aren’t a box-ticking exercise; they’re a proactive safety measure that can save lives, reduce costs, and prevent major disruption. The traffic light system provides clarity and direction so you can take the right action at the right time.

If it’s been over a year since your last racking inspection—or if your site has experienced damage or changes—it’s time to book an expert inspection.

Book a Racking Inspection with Confidence

At A-Z Rack Inspections Ltd, we help logistics, retail, and manufacturing businesses stay safe and compliant. All inspections are carried out by SEMA Approved Racking Inspectors, with clear reporting and fast turnaround.

📞 Call us: 07947 886161 or 07917 664940
📧 Email: sales@a-zrackinspections.co.uk

A-Z Rack Inspections Ltd – We don’t just inspect. We protect.

Request a Quote Today

Get a Quote

With over 25 years of experience, our SEMA Approved Racking Inspectors offer nationwide racking inspection and training.

Rack Inspection Blog