IKO in Clay Cross initially approached us in 2018 to carry out an annual racking inspection.
Our Role
This client had never previously undertaken an annual racking inspection, which is not uncommon. During our initial inspection, it quickly became apparent that there were a significant number of red-risk defects throughout the racking system, despite it remaining fully loaded. The racking was being used to store large rolls of plastic, with many bays operating close to their maximum safe load capacity. Given the combination of severe damage and high loading, the condition of the installation presented a significant safety risk that required immediate attention.
The Solution
It also became apparent at an early stage that the client had a significant issue with staff identifying and reporting damage to the racking. As a result, defects were often left unreported, allowing damage to worsen over time and increasing the likelihood of serious structural failures. This highlighted the need not only for remedial repairs but also for improved staff awareness and the implementation of robust damage reporting procedures.
Following discussions with the management team, it became evident that staff had not received adequate training to identify racking damage or understand the damage tolerances defined within SEMA guidelines. As a result, damage that should have been reported and addressed was often overlooked, increasing the risk of unsafe racking remaining in service. It was clear that, alongside the required repairs, the client would benefit from a structured racking safety awareness programme to ensure staff could recognize damage, understand the associated risks, and report defects promptly.
Implementation & Delivery
We were subsequently instructed to attend site and deliver a comprehensive racking safety awareness training program to all forklift truck (FLT) operators. The training was designed to ensure that operatives understood how to identify and categorize racking damage in accordance with SEMA guidelines, recognize the different risk classifications, and understand the appropriate actions required for each category. This enabled staff to report damage accurately and promptly, helping to prevent unsafe racking from remaining in service and significantly improving the client’s overall racking safety management.
Results & Impact
Today, all members of staff fully understand how to identify and categorise damaged racking components in accordance with SEMA guidelines. The client has implemented a highly effective damage reporting procedure, with management actively encouraging employees to report any damage as soon as it is identified. This proactive approach has created a strong safety culture within the warehouse, ensuring that damaged components are assessed and the appropriate corrective actions are taken promptly. As a result, the client has significantly reduced the risk of damaged racking remaining in service and has established a sustainable system for maintaining the ongoing safety and integrity of its storage installation.
We now attend the site annually to carry out the client’s statutory racking inspections, providing ongoing support to ensure the storage installation remains safe, compliant, and well maintained. The strength of our working relationship has continued to grow, and we have since been appointed to design, supply, and install a substantial racking system within one of the client’s new warehouse facilities. This continued partnership demonstrates the confidence the client has in our expertise, the quality of our service, and our commitment to improving warehouse safety.
Client Testimonial
Iko at Clay cross Chesterfield has for many years employed the Sde group to install, maintain, and inspect our racking across both of our warehouse and production sites.
The SDE aim from our prospective is to help, develop and understand the implications of poor management of racking and its repairs to which we have seen a dramatic fall in damages and repairs through some good direction from the Sde inspectors and installers.
Polite, professional, and understanding is what I can say for the Inspectors we have attend site for our racking inspections, who give clear information on issues, actions, and remedial works through comprehensive reports.
A big thank you for the continued support.
Wayne Jackson
