Why ASRS Inspections Matter: A Simple Guide to Staying Safe and Compliant with HSG76

ASRS Inspections Matter

Modern warehouses are changing fast. Automated Storage and Retrieval Systems (ASRS) and high-bay pallet racking systems help businesses store more products, improve efficiency, and reduce manual handling. But with automation comes responsibility, especially when it comes to safety inspections.

For many warehouse operators, terms like ASRS, PRRS, high-bay racking, and HSG76 can sound technical and confusing. This guide explains everything in simple language, helping warehouse managers, operations teams, and business owners understand why regular ASRS inspections are essential.

What Is an ASRS System?

An Automated Storage and Retrieval System (ASRS) is a warehouse storage system that uses machines, conveyors, cranes, or robots to automatically place and retrieve pallets or products from racking.

ASRS System in operation

In simple terms:

  • Instead of forklift drivers manually moving pallets,
  • The automated system handles storage and retrieval,
  • Often inside very tall racking structures.

These systems are commonly found in:

  • Distribution centres
  • Cold storage warehouses
  • Manufacturing facilities
  • E-commerce fulfilment centres
  • High-volume logistics operations

Because ASRS systems often operate at height and behind safety fencing, damage or wear can go unnoticed without proper inspections.

What Is HSG76?

HSG76 – Warehousing and Storage: A Guide to Health and Safety is official guidance published by the UK Health and Safety Executive (HSE). It provides practical advice on keeping warehouse operations safe.

HSG76 inspections of ASRS

The guidance specifically highlights the importance of inspecting automated and high-bay racking systems.

According to HSG76:

“Automated and high-bay systems, however, while less prone to damage at high level, require inspection and the higher levels cannot be seen from the ground.”

This means that even if damage is not immediately visible, it may still exist, and hidden damage can create serious safety risks.

Why Do ASRS Systems Need Regular Inspections?

Many businesses assume that because ASRS systems reduce forklift impacts, they require less attention. While automation may reduce some risks, it introduces others.

Common Issues Found During ASRS Inspections

Regular inspections can identify:

  • Bent or damaged racking uprights
  • Loose or missing fixings
  • Impact damage
  • Misaligned rails
  • Fatigue cracks
  • Damaged bracing
  • Corrosion
  • Wear caused by automated cranes or shuttles
  • Structural movement over time
  • Damaged pallets or incorrect types of pallets stored in system
  • Issues caused by loads on pallets

Without inspections, small problems can develop into major failures.

The Hidden Risk with High-Bay Racking

One of the biggest challenges with ASRS systems is visibility.

Unlike conventional pallet racking, ASRS systems are often:

  • Extremely tall
  • Enclosed
  • Restricted-access
  • Operating continuously

HSG76 warns that upper levels cannot usually be inspected from ground level.

This means specialist inspection methods are often required, including:

  • Elevated access equipment
  • Drone-assisted inspections
  • Detailed structural assessments
  • Specialist rack inspection reports

What Does HSG76 Recommend?

HSG76 recommends a formal inspection process for automated racking systems. The guidance includes:

1. Immediate Reporting of Problems

Warehouse teams and maintenance engineers should report any signs of damage immediately so trends and recurring issues can be identified. A reporting system should be in place to record and issues.

2. Expert Inspections Every 12 Months

An expert inspection every 12 months consisting of a minimum of 20% of theinstallation carried out on a rolling basis so that the complete installation isinspected every five years as a minimum requirement.

These inspections should be carried out by a competent person, such as a SARI (SEMA Approved Racking Inspector).

3. Ongoing Rolling Inspections

HSG76 advises that inspections should be carried out on a rolling basis so the entire installation is inspected over time.

4. Keeping Inspection Records

Businesses should maintain records of:

  • Inspections
  • Damage reports
  • Repairs
  • Risk classifications

The HSE states these records should be kept in a logbookand reviewed by the PRRS (Person Responsible for Racking Safety)to identify if a more wide-ranging inspection or other action is necessary.

Understanding Rack Damage Risk Levels

HSG76 classifies rack damage into three categories:

Green Risk – Monitor Only

Minor issues that are safe for continued use but should be monitored during future inspections.

Amber Risk – Action Required Soon

Damage serious enough to require corrective action as soon as possible.

Affected areas should not be reloaded until repairs are completed.

Red Risk – Immediate Action Required

Severe damage creating an immediate safety risk.

The affected area should be unloaded immediately and isolated from use until repaired.

Who Is Responsible for ASRS Safety?

Under UK health and safety law, warehouse operators and employers are responsible for ensuring storage systems remain safe.

This includes:

  • Conducting regular inspections
  • Maintaining the racking system
  • Repairing damage promptly
  • Keeping safety records
  • Ensuring staff report defects

Failing to manage racking safety can lead to:

  • Product damage
  • Downtime
  • Injuries
  • Prosecution
  • Insurance complications

Why Professional Rack Inspections Matter

ASRS systems are specialist installations that require specialist knowledge.

A professional rack inspection helps:

  • Identify hidden structural issues
  • Reduce risk of collapse
  • Improve compliance with HSG76
  • Support insurance requirements
  • Reduce operational downtime
  • Extend the life of the installation

At SEE Racking Inspections, we provide independent inspections for:

  • ASRS systems
  • High-bay racking
  • Pallet racking
  • Shuttle systems
  • Automated warehouses
  • Industrial storage systems

Signs Your ASRS System May Need Attention

Inspecting an ASRS System

You should arrange an inspection if you notice:

  • Unusual noises from automated cranes
  • Damaged rack protectors
  • Misaligned pallets
  • Leaning racking
  • Visible impact damage
  • Repeated faults in automated equipment
  • Missing safety signage
  • Loose floor fixings
  • Increased maintenance issues

Even small signs can indicate larger structural problems.

How Often Should ASRS Systems Be Inspected?

A good inspection programme usually includes:

Inspection TypeRecommended Frequency
Visual internal checksWeekly
In-house formal inspectionMonthly
Expert SARI inspectionEvery 12 months (minimum of 20% of the system)
Additional inspectionsAfter impacts, changes to the system or other concerns

High-activity warehouses may require more frequent inspections.

Final Thoughts

Automated warehouse systems improve efficiency, but they do not remove the need for safety inspections.

In fact, because ASRS systems operate at height and much of the structure is hidden from view, inspections become even more important.

HSG76 clearly recommends that experts inspect equipment, keep records, and take prompt action when they identify damage.

By investing in regular ASRS inspections, businesses can:

  • Protect employees
  • Reduce downtime
  • Stay compliant
  • Avoid costly failures
  • Improve warehouse safety

Need an ASRS Inspection?

SEE Racking Inspections provides professional rack inspections across the UK for automated storage systems, pallet racking, and warehouse storage equipment.

Contact us today to discuss your ASRS inspection requirements and ensure your warehouse remains safe, compliant, and operational.

Understanding UK Legislation for Racking Safety: HSE, PUWER & SEMA Standards

UK Legislation for Racking Safety

As safe as your warehouse racking may appear, there are an estimated 700 racking collapses in the UK every year. That’s 2 a day, resulting in costs of approximately £1.5 billion in replacements, repairs, lost inventory, and, perhaps most importantly, legal claims.

The Health and Safety Executive (HSE) makes it clear that ignorance of the law is no defence. Whether you’re a warehouse manager or a business owner, understanding the interplay between HSE guidance, PUWER regulations and SEMA standards is central to staying compliant.

In this article, we’re going to walk you through the main points you need to know and how companies like SEE Racking Inspections can keep your warehouse from joining that unfortunate list of 700.

Key takeaways

  • Racking is typically treated as work equipment: In most warehouse environments, pallet racking falls within the scope of the Provision and Use of Work Equipment Regulations 1998 (PUWER), meaning it must be suitably maintained and inspected by competent persons.
  • A three-tier inspection approach is recommended: Compliance is commonly achieved through a combination of regular visual checks, periodic in-house reviews, and an annual inspection by a competent specialist.
  • Appointing a PRRS is strongly recommended: Warehouses are encouraged under HSE guidance to appoint a Person Responsible for Racking Safety (PRRS) to oversee inspections, repairs and reporting processes.
  • Follow the SEMA Traffic Lights: Damage is typically categorised using the widely adopted system developed by the Storage Equipment Manufacturers’ Association (SEMA): Green (monitor), Amber (repair within a defined timeframe) and Red (immediate action required).
  • Independent oversight is vital: Using an independent inspector means your safety check is unbiased, focusing purely on safety and compliance (as opposed to using it as an opportunity to sell you racking products).

The legal foundation: Health and Safety at Work etc Act 1974

Every safety discussion in the UK begins with the Health and Safety at Work etc. Act 1974. This act places a “duty of care” on employers to safeguard the health, safety and welfare of their employees (as far as is reasonably practical).

In a warehouse context, this means the environment including storage systems must be safe for use under day-to-day operating conditions. If a racking system collapses due to neglected maintenance or inadequate oversight, the business (and potentially its directors) can be held liable. The 1974 Act acts as the umbrella under which more specific regulations sit, giving the HSE the power to issue improvement notices or prosecute where necessary.

PUWER 1998: Racking as work equipment

The Provision and Use of Work Equipment Regulations 1998 (PUWER) is one of the most important regulations for racking safety. While often associated with machinery, PUWER applies more broadly to equipment used at work, which can include static storage systems such as pallet racking.

Regulation 6 of PUWER is particularly relevant. It requires that equipment be inspected:

After installation to ensure it’s been assembled correctly and is safe to use.

After relocation or major alteration as structural integrity may be affected.

At suitable intervals based on risk, usage and the potential for deterioration.

Because racking is regularly exposed to impacts from forklifts and varying load conditions, it’s generally considered equipment that can deteriorate over time. As such, regular, recorded inspections by a competent person are essential for compliance (although the exact frequency is determined by risk assessment rather than fixed in law).

HSE Guidance: The HSG76 Standard

While PUWER sets out what must be done, HSG76 Warehousing and Storage: A Guide to Health and Safety explains how to manage warehouse risks effectively.

HSG76 recommends a structured inspection regime to make sure any damage or deterioration is identified early.

The Three-tier Inspection Hierarchy

1. Weekly visual checks: Conducted by a trained and competent person to identify obvious issues such as bent uprights, dislodged beams or missing safety components.

2.  Monthly Reviews: A more systematic review to identify recurring damage patterns or operational risks.

3.  Annual Expert Inspections: A detailed assessment carried out by technically competent specialists—normally by SEMA-Approved Racking Inspectors (SARI).

SEMA: The Industry Benchmark

The Storage Equipment Manufacturers’ Association (SEMA) is the leading trade body for the storage equipment industry in the UK. While not a regulator, its guidance is widely recognised and referenced within HSE materials.

SEMA developed the widely used “Traffic Light” system to classify racking damage:

Green Risk: Damage within acceptable limits that should be monitored.

Amber Risk: Damage that exceeds recommended limits, and should be repaired within a defined timeframe (commonly up to 4 weeks)

Red Risk: Severe damage that requires immediate offload and isolation.

Following this system helps keep your maintenance workflow structured and risk-based in its approach.

The role of the PRRS (Person Responsible for Racking Safety)

HSG76 strongly recommends appointing a Person Responsible for Racking Safety (PRRS) to manage and coordinate racking safety processes.

This individual typically:

  • Acts as the main point of contact for racking safety issues.
  • Coordinates with external inspectors and makes sure repair work is completed.
  • Maintains the “Racking Log,” which tracks every inspection, damage report and repair.
  • Ensures that staff are reporting damage immediately, creating a “no-blame” culture where drivers aren’t afraid to report a collision.

What this Means for Warehouse Operators?

In recent years, the emphasis on competence has increased significantly. The HSE expects businesses to demonstrate that individuals carrying out inspections are properly trained and capable of identifying risks.

Simply carrying out informal checks without evidence of competence or record-keeping may not be sufficient to demonstrate compliance.

Key compliance checklist:

Appoint a PRRS: Make sure they have the appropriate authority and training.

Display load notices: Clearly show safe load limits on all racking.

Maintain an inspection log: Keep accurate records of checks, findings and actions.

Arrange competent repairs: Use suitably qualified professionals and appropriate components.

How SEE Racking Inspections Can Help?

Even this brief list shows how much there is to consider when it comes to racking safety and compliance. You don’t need to manage it on your own, however. At SEE Racking Inspections, we specialise in helping businesses achieve compliance while maintaining operational efficiency.

Annual Inspections by SEMA-Approved Inspectors: Our SARI-qualified inspectors provide the independent, unbiased reports required by the HSE and insurers.

Rack Safety Awareness Training: We train your team to carry out daily and weekly checks confidently, ensuring your PRRS is fully prepared for the role.

Unbiased Advice: We don’t manufacture or sell racking. We focus our reports solely on your safety, so they address what you need not what we want to sell.”

When you partner with us, you do more than meet HSE requirements. You protect your staff, your stock, and your business’s future. Get in touch with SEE Racking Inspections and gain expert, independent advice you can depend on.