Last updated: June 2026 | By Spode Storage Solutions
If a racking bay collapses in your warehouse and a worker is injured, your business carries direct legal liability under the Occupational Health and Safety Act. Most warehouse operators know racking safety matters. Fewer know what the law actually requires, what a SEMA inspection involves, and what a classification of RED on your inspection report means for your operations.
This guide covers the legal framework, the inspection requirements, and the specific obligations every warehouse operator in South Africa needs to understand.
The legal framework for racking safety
Racking safety sits under the Occupational Health and Safety Act 85 of 1993. The Act requires every employer to provide and maintain a workplace that is safe and without risk to the health of employees. Racking qualifies as plant and equipment under the Act, which means your obligations apply directly to every storage system in your facility.
The General Safety Regulations, published under the OHS Act, add specific requirements for the stacking and storage of goods, covering structural stability and the frequency of safety assessments.
SEMA standards are not South African legislation, but they are the most widely recognised technical benchmark for racking safety, and compliance with them demonstrates due diligence under the OHS Act. If your racking causes an injury and you have no record of inspections or recognised safety standards followed, that gap becomes evidence of negligence.
Key legislation: Occupational Health and Safety Act 85 of 1993 | General Safety Regulations (under the OHS Act) | SEMA Code of Practice for static racking.
SEMA, SARI, and the PRRS role
The Storage Equipment Manufacturers’ Association (SEMA) publishes the most widely referenced technical guidelines for racking inspection. SEMA is UK-based, but its standards are the practical benchmark used by racking suppliers and inspectors across South Africa.
A SEMA Approved Racking Inspector (SARI) is a qualified external specialist who has completed a three-day SEMA training course, a written examination, and a practical assessment. SARI reports carry weight with insurers and legal bodies, and an annual SARI inspection is the minimum standard for formal compliance.
Alongside the external SARI, your business must appoint a Person Responsible for Racking Safety (PRRS). The PRRS is an internal role: a designated employee who oversees day-to-day racking safety, conducts and documents regular walk-through checks, reports damage, and maintains inspection records. The PRRS does not replace the SARI. They work together.
How often must racking be inspected?
A formal SARI inspection must occur at least once every 12 months. In higher-risk environments such as cold stores or facilities with intensive forklift traffic, SEMA recommends considering a twice-yearly inspection cycle based on your risk assessment. For newly installed racking, your supplier should advise on the appropriate timing for the first formal inspection.
Inspections must also be triggered by specific events, regardless of when the last scheduled inspection took place:
- A forklift impact on any upright or beam
- A partial or full racking collapse
- Overloading of any bay
- Any modification to the racking layout or configuration
Between formal inspections, your PRRS should conduct monthly walk-through checks. These are visual, not structural, but they must be documented. SEMA specifies acceptable upright tolerances: a lean of no more than 5mm per 1,000mm measured parallel to the aisle, and no more than 3mm per 1,000mm measured perpendicular to the aisle. Any upright outside these tolerances should be flagged for assessment.
The SEMA traffic light system
SEMA inspections classify damage using a three-colour system. Every classification carries a mandatory response.
| Colour | Status | Required action |
| GREEN | Safe to use | Record the finding and monitor at every future inspection. Green does not mean ignore. |
| AMBER | Damage present | Repair within 4 weeks. An AMBER classification not actioned within 4 weeks automatically escalates to RED. The bay may remain in use in the interim under load conditions specified by the inspector. |
| RED | Immediate risk | Offload the bay immediately. Do not use it until the damage has been repaired and re-inspected. RED indicates a structural collapse risk. |
Keep all inspection reports on file. If a workplace injury occurs and you cannot produce documentation, your liability position is significantly worse.
No welding. No straightening. Replacement only.
One of the most common mistakes in racking maintenance is attempting to repair damaged uprights or beams by welding or straightening them. SEMA prohibits this practice. Racking components are manufactured from cold-formed steel. When steel is cold-formed, the manufacturing process work-hardens the material. Welding or bending it back introduces heat and stress that permanently compromises its structural integrity.
A straightened upright can look fine and still fail without warning. Damaged components must be replaced like-for-like, using parts specified by the original manufacturer.
Load notices: the specifics
Every racking bay must display a load notice showing the maximum load per bay and per beam level. SEMA specifies the format: A3 landscape, displayed prominently and in colour so it is clearly visible to warehouse operatives. A missing, illegible, or monochrome load notice is classified as an AMBER risk at inspection.
Spode provides load ratings for every system it supplies and installs. If your current racking has no visible load notices, contact your supplier before your next inspection and confirm the correct figures in writing.
Staff training and documentation
The OHS Act places a duty on employers to train staff on the safe use of work equipment. For racking, this means your warehouse team must know the load limits per bay and level, how to identify and report visible damage, and who is responsible for escalating a concern. A documented induction record showing what was covered, who attended, and when is sufficient evidence of compliance. The training does not require a formal qualification.
What non-compliance costs
A Department of Employment and Labour inspection can result in a notice to remedy, an administrative fine, or a prohibition notice halting operations in the affected area. If an injury or fatality occurs in a non-compliant facility, directors and managers can face personal criminal liability under the OHS Act.
The cost comparison: a SARI racking inspection costs a fraction of the fines, legal fees, or compensation that follow a workplace injury or OHS Act violation. Compliance is not overhead. It is risk management.
Book a professional racking assessment
Your next Department of Labour inspection will not care when you last checked. A professional racking assessment from Spode gives you a clear compliance picture before anyone else does.
Spode offers a full range of racking systems and a professional racking and shelving audit covering structural integrity, load ratings, floor anchoring, load notices, and compliance documentation.
Frequently asked questions
How often does warehouse racking need to be inspected in South Africa?
Formal expert inspections by a SARI-qualified inspector are required at least once every 12 months. In higher-risk environments such as cold stores or facilities with intensive forklift activity, SEMA recommends considering a twice-yearly inspection cycle based on your risk assessment. Inspections are also required after any incident that could have affected the racking structure.
What is the PRRS and do I need one?
PRRS stands for Person Responsible for Racking Safety. It is an internal role within your business, separate from the external SARI inspector. Your PRRS conducts and documents regular walk-through checks, maintains inspection records, and manages the response to any damage found. Appointing a PRRS is part of meeting your duty of care under the OHS Act.
What happens if an AMBER damage classification is not repaired?
AMBER damage must be repaired within 4 weeks. If it is not, it automatically escalates to RED, meaning the affected bay must be taken out of service immediately. The bay may remain in use during the 4-week window, but only under the load conditions specified by the inspector.
Can I straighten or weld a damaged racking upright?
No. SEMA prohibits welding or unauthorised straightening of damaged racking components. Racking is manufactured from cold-formed steel, and the work-hardening process that occurs during manufacturing means any subsequent welding or bending compromises structural integrity. Damaged components must be replaced like-for-like with manufacturer-specified parts.
What are the requirements for racking load notices?
Every racking bay must display a load notice in A3 landscape format, clearly visible to warehouse operatives. The notice must state the maximum load per bay and per beam level, and must be in colour and remain legible at all times. A missing, monochrome, or illegible load notice is classified as an AMBER risk at inspection.