Safety Inspections
Find Rack Problems Before OSHA Does, or Before Someone Gets Hurt
We perform thorough on-site rack inspections, document every finding with photographic evidence, and give you a clear remediation plan, so you know exactly where your system stands and what to do about it.
Warehouse rack safety inspections are systematic evaluations of pallet racking systems to identify structural damage, overloading, and code violations that could cause collapse or injury. Inspections follow standards established by the Rack Manufacturers Institute (RMI) and ANSI MH16.1, and are recommended annually or after any forklift impact.
The Challenge
Rack Damage Doesn't Announce Itself Until It's Too Late
Forklift strikes, overloaded bays, and bent uprights often go unreported in busy warehouses. Damaged racking doesn't fail immediately. It weakens gradually until catastrophic collapse occurs without warning. OSHA requires racking to be inspected regularly by a "competent person," and failure to maintain inspection records can result in citations of $17,000 or more per violation. The average rack collapse costs $2–5 million in direct and indirect expenses. Professional inspections cost a fraction of one accident.
A documented inspection program is your proof of due diligence, and your early warning system before a minor repair becomes a major incident.
What You Get
Everything Included, No Surprises
Comprehensive On-Site Inspection
We walk every aisle and inspect every upright, beam, connector, anchor, and load for damage, deformation, misalignment, and overloading, using RMI, ANSI MH16.1, and OSHA standards as our benchmark. Calibrated measuring tools verify alignment; critical issues are tagged and communicated immediately.
Written Report with Severity Classifications
Every inspection produces a detailed written report, delivered within 5 business days, with photographic documentation, rack-by-rack condition assessment, and prioritized repair recommendations using RMI severity ratings: Green (no action), Yellow (monitor), Orange (reduce load), Red (immediate offload).
Internal Inspection Program Support
OSHA also requires regular internal inspections by facility personnel. We train your supervisors to perform monthly inspections, develop customized checklists and documentation systems, and provide ongoing support as your team conducts their own checks between annual professional inspections.
How It Works
A Clear Process, Start to Finish
Pre-Inspection Planning
We coordinate scheduling to minimize operational disruption, review facility drawings and any previous inspection reports, and understand your specific concerns or known problem areas. Our inspectors arrive equipped with proper tools, safety gear, and documentation systems.
Systematic Field Inspection
Inspectors walk every aisle examining racking systematically. We use calibrated measuring tools for alignment verification, take extensive photos documenting conditions and damage, tag critical issues requiring immediate attention, and record detailed observations in our inspection database.
Damage Assessment & Severity Rating
We categorize all damage using RMI severity classifications: Green (no action required), Yellow (monitor and schedule repair), Orange (reduce load capacity immediately), and Red (offload section, do not use until repaired). This prioritization helps you allocate resources based on actual risk.
Comprehensive Reporting
Within 5 business days, you receive a detailed inspection report including an executive summary, rack-by-rack condition assessment with photos, and prioritized repair recommendations with cost estimates. Reports are formatted for OSHA, insurance, and audit purposes.
Follow-Up & Repair Support
We don't just identify problems, we help solve them. Our team provides repair quotes, coordinates component procurement, schedules installation, conducts post-repair verification, and can train your team on ongoing internal inspection procedures.
Scope of Work
Installations We Handle
Annual Comprehensive Inspections
Our most thorough service meets ANSI MH16.1 and RMI guidelines. Certified inspectors examine every rack system in your facility, documenting conditions with photos and detailed reports. Recommended for all facilities annually or after significant operational changes.
Quarterly Safety Audits
High-activity warehouses benefit from more frequent review. Quarterly audits focus on damage assessment, overloading identification, and critical safety issues, catching developing problems between annual inspections. Ideal for 3PLs, high-velocity operations, and facilities with a history of forklift damage.
Post-Incident Damage Assessments
After forklift collisions, overloading incidents, or suspected damage, prompt assessment is critical. We schedule inspectors as quickly as possible to evaluate damage extent, determine if affected racks can remain in service, and provide documentation for insurance claims.
Internal Program Development & Training
We train your supervisors and maintenance staff to perform monthly internal inspections, covering damage recognition, severity assessment, documentation requirements, and corrective action procedures. Graduates receive certificates documenting competent-person status under OSHA guidelines.
The Difference
Why Facilities Teams Choose Hammerhead
OSHA & Insurance Documentation
OSHA citations for uninspected racking run $17,000+ per violation, and that's before any accident. Our inspectors hold OSHA 30-Hour General Industry certification, RMI Certified Inspector training, and PE licenses for structural assessments, with 10+ years average field experience and manufacturer-specific training on Interlake, Ridg-U-Rak, Mecalux, and others. Reports meet OSHA documentation requirements and demonstrate due diligence to your insurance carrier.
Catch Damage Before It Compounds
Minor rack damage is inexpensive to repair. The same damage left six months is often a full component replacement, or a collapse that closes your operation. The average rack collapse costs $2–5 million in direct and indirect expenses. Early inspection prevents escalation.
Clear Priority Framework
Our four-tier severity classification (Green, Yellow, Orange, Red) tells you what to fix today, what to schedule, and what to monitor. No ambiguity, no guesswork. You make budget decisions based on risk, not instinct.
On-Call After Incidents
Forklift struck a rack after hours? We prioritize post-incident damage assessments and schedule an inspector as quickly as location and availability allow, evaluating whether affected sections can remain in service, recommending repairs, and providing documentation for insurance claims.
Common Questions
Frequently Asked Questions
How often should racking be inspected?
ANSI MH16.1 recommends annual professional inspections plus frequent internal inspections (monthly is typical for active facilities). High-activity operations or those with a history of damage benefit from quarterly professional inspections. After any significant impact or suspected damage, immediate inspection is required regardless of schedule.
What happens if critical damage is found?
Red-tagged damage requires immediate action. We recommend offloading affected sections until repairs are completed. Our team can expedite component procurement and installation to minimize downtime. Continuing to use critically damaged racking creates unacceptable safety risk and OSHA violations.
Can you inspect while our facility is operating?
Yes. Our inspectors work around your operations, coordinating with warehouse staff to access aisles safely. We typically schedule inspections during less busy periods to minimize interference but can accommodate any schedule, including nights and weekends.
Do your inspection reports satisfy OSHA requirements?
Our comprehensive inspection reports meet OSHA documentation requirements and align with ANSI MH16.1 standards. They demonstrate that you've taken reasonable steps to identify hazards and maintain safe conditions, which are critical elements of OSHA compliance and due diligence in liability claims.
What's included in the inspection fee?
Our flat-rate inspection fees include on-site field inspection by certified personnel, comprehensive photo documentation, a detailed written report with prioritized recommendations, and consultation on findings. Repair work is quoted separately. Most inspections pay for themselves by identifying issues before they require emergency repairs.
What We Find
Common Hazards Our Inspectors Identify
Forklift Impact Damage
The most common racking issue by far. Impacts bend uprights, dislodge beams, damage base plates, and compromise structural integrity in ways that aren't always visible from the aisle. Even minor-looking damage can reduce load capacity by 50% or more. Our inspectors assess whether damaged components can be repaired or require immediate replacement.
Overloading
Racking is often overloaded gradually as operations evolve. Pallets get heavier, products change, or beam configurations are modified without engineering review. We compare actual loaded weights to rated capacity placards, identify sections at risk, and recommend capacity upgrades or operational changes before overloading causes a failure.
Missing or Inadequate Anchoring
Racks must be properly anchored to prevent tipping, especially in seismic zones. Missing anchors, undersized fasteners, or concrete deterioration around anchor points create catastrophic failure risk. We verify anchor installation, assess concrete conditions, and recommend remediation before an incident makes it a legal matter.
Corrosion & Improper Modifications
Moisture, chemicals, and condensation cause steel corrosion that reduces load capacity and creates brittle failure risk. Equally dangerous: unauthorized field modifications (welding, cutting components, or mixing incompatible systems) that void warranties and create unpredictable failure modes. We identify both and document the corrective action required.
Most facilities don't realize they have a problem until something fails. A proper inspection catches damaged uprights, overloaded beams, and missing anchors before they become safety incidents. We document everything so there's a clear path to getting it fixed.
Ivan Garcia
Director of Project Management, Hammerhead Warehouse Systems
Related Services
Repair & Maintenance
When an inspection finds damage, we repair it: component replacement, upright replacement, and full load verification before the bay goes back into service.
Learn More →
Permits & Compliance
Inspection documentation pairs with your permit records to give you a complete compliance history for audits and insurance reviews.
Learn More →
Design & Layout
If an inspection reveals clearance or capacity issues, we can redesign affected areas to bring the system into compliance.
Learn More →Schedule Your Rack Safety Inspection
Don't wait for an incident or OSHA citation. Schedule an inspection and we'll walk your facility, document every finding, and give you a prioritized remediation plan. Flat-rate pricing, no surprises.
Get a Free Consultation