INSPECTION REPORT

ON BEHALF OF

Head Office:

Stark Industries
1200 Industrial Avenue
Long Beach
CA 90803

Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries

 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries

Contents:

1. General
2. SAFETY ISSUES
3. General Inspection Findings
4. Repairs

Appendix 1: Damage to Racking

Appendix 2: Damage Limitations
Appendix 3: Typical Rack Inspection Procedures
Appendix 4: Repair & Maintenance Procedures
Appendix 5: Contact Details
Appendix 6: Outline Plan (Not to scale)

Site Address: Stark International

Technology Park
Fordwich
Nr Canterbury

Site Contact: Miss Pepper Potts

Date of Inspection: Monday 4th April 2022

Date of next inspection: Monday 3rd April 2023

Inspector:
Colin Dowding DipNEBOSH SQRI
SEMA Qualified & Trained Rack Safety Inspector
Health & Safety Officer

2
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries

1.0 - General
Colin Dowding was requested to visit the Stark International Technology Center in Fordwich, Nr Canterbury to
undertake an inspection of the racking & shelving on site. The inspection took place on Monday 4th April 2022.
The inspection was carried out at Ground Level with a visual inspection of the exterior and other reasonably accessible
components.
There have been no previous Inspections at this site.

It is not guaranteed that ALL components of the different racking systems were fully inspected due to stock placement,
it is strongly recommended that all staff undertake regular checks of the racking on site.

Appendix 1: Damage to Racking

Location Description of Damage Designation Action Required

Layout as per our attached drawing (Appendix. 5)

Racking Specification:
Frames: M Duty Uprights throughout
5500mm Tall
1100mm Deep
1200mm Brace Gate

Beams: x3 & x4 Levels Per Bay

85 x 40 x 2700 Box Beam
135 x 50 x 3300 Box Beam (Tunnel Areas Only)
To First Beam: 1950mm
Pitch: 1420mm
Footplates: B1 with x2 Floor Fixings Per Footplate

3
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Overall Site Issues Found:

12
Green Notifications

3
Amber Notifications

2
Red Notifications

4
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Appendix 1: Damage
Location Damage Risk Remedial Action

Row A
No Damage Found During the Inspection

Row B
Bays 9 / 10 3rd Diagonal Brace Badly Damaged AMBER Replace Brace
No Further Damage Found During the Inspection

Row C
Bays 4 / 5 Front Upright Slight Damage GREEN Periodic Assessment
No Further Damage Found During the Inspection

Row D
Bays 3 / 4 (Tunnel) 1st Horizontal Brace Damaged AMBER Replace Brace
No Further Damage Found During the Inspection

Row E
Bays 2 / 3 (Tunnel) Front Upright Slight Damage GREEN Periodic Assessment
Bays 6 / 7 Front Upright Slight Damage GREEN Periodic Assessment
No Further Damage Found During the Inspection

Row F
Bays 3 / 4 (Tunnel) Front Upright Badly Damaged RED Replace Upright
No Further Damage Found During the Inspection

Row G
Bays 2 / 3 (Tunnel) 3rd Diagonal Brace Slight Damage GREEN Periodic Assessment
Bays 4 / 5 Front Upright Slight Damage GREEN Periodic Assessment
Bays 9 / 10 Front Upright Slight Damage GREEN Periodic Assessment
No Further Damage Found During the Inspection

Row H
Bays 6 / 7 Front Upright Slight Damage GREEN Periodic Assessment
No Further Damage Found During the Inspection

Row J
Bays 3 / 4 Front Upright Slight Damage GREEN Periodic Assessment
No Further Damage Found During the Inspection

Row K
Bays 4 / 5 Front Beam Safety Clip Missing RED Fit New Pin
Bays 7 / 8 Front Upright Slight Damage GREEN Periodic Assessment
Bays 8 / 9 Front Upright Slight Damage GREEN Periodic Assessment
No Further Damage Found During the Inspection

5
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Appendix 1: Damage Cont.:
Location Damage Risk Remedial Action

Row L
Bays 7 / 8 Front Upright Slight Damage GREEN Periodic Assessment
Bays 8 / 9 Front Upright Slight Damage GREEN Periodic Assessment
No Further Damage Found During the Inspection

Row M
Bays 2 / 3 Front Upright Badly Damaged AMBER Replace Upright
Bays 3 / 4 Front Upright Slight Damage GREEN Periodic Assessment
Bays 5 / 6 Front Upright Slight Damage GREEN Periodic Assessment
No Further Damage Found During the Inspection

Photos:

6
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
All AMBER and RED items should be repaired in accordance with the time scales indicated in this report.

Shelving
X6 Rows of Shelving within the warehouse, no damage or issues found in relation to build of damage.
Load Notices are attached to each row of shelving.

3.0: General Inspection Findings

The general condition of the adjustable pallet racking is very good, there is a small amount evidence of
localized damage, all damaged items found / seen during the inspection are detailed above.
Please note that only the racking visible during the inspection can reported upon, due to the excessive stock
placed within the aisles it was impossible to fully inspect all of the racking.

Generally, the racking observed was in a good, serviceable condition but attention is required with regards to
maintenance and regular monthly checks being carried out.

The warehouse itself was very much overstocked with product, navigating the aisles was very difficult with
stock and palletised goods in nearly every aisle (In some cases product is stacked very high), this is a recipe for
damage to be caused, not only to the racking but also product, the Flexi Truck is a large forklift and will / can
cause damage very easily, keeping aisles free of stock should be a priority within any warehouse,
unfortunately due to the limited space available and the amount of stock incidents are inevitable.

The general level of tidiness was very good, and the floors were free from debris, no plastic loose in the
racking and all aisles were clear and clean.

The floor within the building is concrete and appears to be in good condition appropriate for the racking
installation. No measurement of the floor slab was taken, and the slab is not within the scope of the
inspection.

3.1: Installation
The racking appears to have been competently installed though regular maintenance / repairs needs to be
addressed.

3.2: Damage
Any damage is noted in accordance with the Manufacturers guidelines in Appendix 1

3.3: Pallets
There are a large number of pallets in use, they appear to be of mixed origin, but condition seems good with
no damaged pallets that could be seen within the racking, all pallets were the correct size and orientation and
suitable for the application.

3.4: Load Notices

Load notices are fitted on each of the pallet racking runs & shelving within the warehouse.

7
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
3.5: Racking Inspections
This is the 2nd Inspection to have been carried out at this facility, the overall condition has improved greatly in
the past 12 months with all recommended repairs being carried out from the 2020 report.

It is recommended that a number of staff are trained as PRRS (Person Responsible for Rack Safety) and carry
out weekly / monthly inspections.

Please contact us if you would like to know more about our PRRS Course

4: Recommendations
It is very evident that a large number of uprights are getting damaged either via the forklift or the movement of stock,
it is recommended that the main Tunnel areas have L-Shape Column Guards fitted to help protect against impact.
I would also recommend the use of upright guards throughout the warehouse:

The Foam / ABS Type would be suitable for this situation and offer some protection against impact damage:
Please contact us for more information and pricing on this type of guard.

4.0: Recommendation for repairs to damaged components

Replacement components should be of the same design and specification and sourced from the original
manufacturer, the exact dimensions of components should be checked with the manufacturer prior to any
remedial work being initiated, dimensions quoted in the report are for guidance only.

To ensure remedial works are carried out to FEM/HSE Standards it is recommended that only competent
Registered Fitters are used.

All items listed within this report must be replaced

HSG (76) - Page 115 Section 642 recommends
To ensure that a racking installation continues to be serviceable and safe, the storage equipment should be
inspected on a regular basis.

The frequency of inspections depends on a variety of factors that are particular to the site concerned and
should be determined by a nominated ‘person responsible for racking safety’ (PRRS) to suit the operating
conditions of the warehouse.

8
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
This will consider the frequency and method of operation together with the dimensions of the warehouse, the
equipment used, and personnel involved, all of which could damage the structure.

It is recommended that to ensure the continued safe & serviceable condition of the shelving & racking
installation, all the detailed recommendations indicated in this report should be followed.
The FEM guide recommends that in addition to an annual inspection by a “Technically Competent Person”,
regular (monthly) visual checks should be made by a designated competent person for the responsibility of
racking safety on site (PRRS).

This person is responsible for ensuring that the racking & shelving is used, inspected & maintained in
accordance with the appropriate regulations & guidelines.

Should you have any queries or require further clarification please do not hesitate to contact me.

Evaluation of Damaged Racking Components

The SEMA Guide classifies damage into the following three categories RED, AMBER & GREEN Risk. Information
on limitations is given below: -

Red Risk
These are items which are severely damaged being at least double the limitations of the Damage Limits Code.
In such circumstances, the racking should be immediately Off-Loaded and isolated from future use until repair
work is carried out.

Amber Risk
Areas where components have been damaged beyond the Damage Limits but less than twice. These are not
sufficiently serious to warrant immediate Off-Loading of the rack. Repairs should normally be carried out
within 4 weeks, should this not happen then the damage should be redefined as RED & treated accordingly.

Green Risk
These are items which are damaged/may require attention but are within the limitations of the SEMA Code.
Such items would be recorded as being still suitable for use but be identified for future reference and
monitoring.
Any “Serious Damage Report” will have been issued on the day of the inspection for all damage designated
RED RISK if applicable.

Any damage will result in a reduced safety margin in the structure & deviations in excess of SEMA limits should
result in the affected area being offloaded.

9
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Assessment of damage to uprights and bracing members

• A steel straight edge 1.0-metre-long is placed in contact with a flat surface on the concave side of the
damaged member such that the damage area lies central as near as possible to the length of the
straight edge.

• For an upright bent in the plane of the frame bracing, the maximum gap between the upright and
straight edge should not exceed 3mm.

• For an upright bent in the direction of the rack beam spans, the maximum gap between the upright
and straight edge should not exceed 5mm.

• For an upright, which has been damaged such that there is a simultaneous bend in both directions,
the left to right and front to back deformation shall be measured separately and the appropriate
limits observed.

• For bracing members bent in either plane, the gap between straight edge and bracing member should
not exceed 10mm.

• These rules apply only to damage, which produces an overall bend in a member, they do not apply to
highly localised damage such as dents, buckles, tears and splits. Localised bends over a length of less
than 1.0metre may be judged pro-rata to the above limits. Members subjected to tears and splits
should be replaced.

Risks Upright bent into the rack Upright bent parallel to Frame Bracing
the beam
Green Up to 3 mm Up to 5 mm Up to 10 mm
Amber Between 3 and 6 mm Between 5mm and 10 mm Between 10 and 20 mm
Red Over 6 mm Over 10 mm Over 20 mm

10
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Damage action procedure flowchart
Racking is damaged

Assess and classify the damage in accordance

with Manufacturers codes

Red Risk Amber Risk Green Risk

Immediately off-load all 1. Identify damage for repair. Record the extent of the
affected bays of racking and 2. Order materials. damage and re-assess at the
repair damage before use. 3. Ensure all locations are not next inspection, but within 12
loaded or reloaded after the months.
goods are removed.
4. Make repairs as soon as
possible.

The necessary repairs or If repairs are not If the severity of

replacements of all damaged carried out within the damage has
parts are correctly carried out. 4 weeks. increased.

Repairs are carried out. If there is no change to the

damage level, continue to
monitor at normal levels and
intervals.

Return to Service Return to Service Continue in Service

11
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Frame damage – measured over 1000mm straight edge

Brace damage – measured over 1000mm straight edge

12
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Assessment of damage to uprights and bracing members

• A steel straight edge 1.0-metre-long is placed in contact with a flat surface on the concave side of the
damaged member such that the damage area lies central as near as possible to the length of the
straight edge.

• For an upright bent in the plane of the frame bracing, the maximum gap between the upright and
straight edge should not exceed 3mm.

• For an upright bent in the direction of the rack beam spans, the maximum gap between the upright
and straight edge should not exceed 5mm.

• For an upright, which has been damaged such that there is a simultaneous bend in both directions,
the left to right and front to back deformation shall be measured separately and the appropriate
limits observed.

• For bracing members bent in either plane, the gap between straight edge and bracing member should
not exceed 10mm.

• These rules apply only to damage, which produces an overall bend in a member, they do not apply to
highly localised damage such as dents, buckles, tears, and splits. Localised bends over a length of less
than 1.0metre may be judged pro-rata to the above limits. Members subjected to tears and splits
should be replaced.
Beam damage – not to exceed tolerance under full load

13
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Assessment of damage to beams

• Beams will naturally deflect under normal loading conditions to a maximum permissible of span/200.
This deflection should disappear when beams are unloaded and should not be confused with
permanent deformation caused by overloading or impact damage.

• Residual vertical deformation should not exceed 20% of normal deflection under load.

• Residual lateral deformation should not exceed 40% of the normal vertical deflection under load.

• Beams which show any clearly visible deformation to the beam end connectors should be unloaded
and replaced.

• Beams which show any signs of cracking to the weld between the beam section and end connector
should be unloaded and replaced.

• A Beam Span of 2700mm / 200 = A Maximum Beam Deflection of 13.5mm

• Any missing locking devices should be replaced immediately to prevent accidental dislodgement of
the beams, it is recommended that a supply of beam locking devices should be retained on site

Appendix 3: Typical Rack Inspection Procedures

Extract from HSE document HSG 76 Warehousing & Storage: a guide to health & safety
Please note this document contains general information regarding health & safety in warehousing & storage
situations, can be downloaded from HSE website at no cost

Racking Inspection and Maintenance

641 In general, racking is manufactured from relatively lightweight materials, as a consequence, there is a limit
to the amount of abuse that it can withstand. The skill of lift truck operators has a great bearing on the
amount of damage likely to be caused. Any damage to racking will reduce its load carrying capacity. The
greater the damage the less its strength will be.

642 To ensure that a racking installation continues to be serviceable and safe, the storage equipment should
be inspected on a regular basis. The frequency of inspections depends upon a variety of factors that are
particular to the site concerned and should be determined by a nominated ‘Person Responsible for Racking
Safety (PRRS) to suit the operating conditions of the warehouse. This will take into account the frequency and
method of operation together with the dimensions of the warehouse, the equipment used, and personnel
involved, all of which could damage the structure. The inspection follows a hierarchical approach using several
levels of inspection.

Immediate Reporting
643 As soon as a safety problem or damage is observed by any employee, it should immediately be reported
to the PRRS. You should have systems in place for reporting damage & defects.

644 Employees should receive training, information & instruction on the safe operation of the racking system.
A formal written record should be maintained.

14
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Visual Inspections
645 The PRRS should ensure that inspections are made at weekly or other regular intervals based on risk
assessment. A formal written record should be maintained.

‘Expert’ Inspections
A technically competent person should carry out inspections at intervals of not more than 12 months. A
written report should be submitted to the PRRS with observations & proposals for any action necessary.

A technically competent person might be a trained specialist within an organisation, a specialist from the rack
supplier, or an independent qualified rack inspector.

Normal rack inspections will be carried out from ground level unless there are indications of problems at high
level that require investigation.

Inspection details and scheduling

Two types of inspection should be carried out as follows:
• End user weekly / monthly inspections. This can be a delegated internal task and incorporated as part
of a routine patrol of the installation, with clear procedures for the recording, reporting, and action
where damage is found.
• Expert inspection yearly or twice-yearly inspections by a ‘technically competent person’ ideally
Qualified and Trained to HSE Standards.
Apart from a more detailed and thorough inspection, it will also ensure that the above actions are
being correctly carried out, recorded, and remedial actions are completed.
It will consider causes of repetitive problems, and then review work practices and training to correct
or improve understanding and usage or racking.

Schedule of inspections
The schedule of inspections varies for each installation, depending on its type, function, and extent of use.
These factors will influence the frequency of audits, i.e.
• A high level of activity within a store will increase the risk of damage. Also consider the work rate
required and skill set for each type of operator and added risk from pick rates.
• The height of the deposit / retrieval operation above ground level and levels of visibility.
• The intricacy of the task, e.g., locating a pallet on to a dynamic system or driving unguided trucks
through the racking.
• A variety of pallet types in operation may lead to additional levels of damage due to placement errors.
• Forklift truck operating aisles, i.e., trucks required to work within the manufacturers’ minimum aisles.
• Forklift truck types, i.e., narrow aisle trucks operating wire or guide rail will be more consistent (and
subsequently creating less damage) than a free roaming counterbalance truck.

15
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
In addition to the annual or bi-annual inspection, an inspection is typically required when any of the following
occur:
• New racking installation – recommended within first 4 months.
• Changes to the installation and layout
• Following changes to materials handling equipment
• Changes to operating patterns, increased usage, or new operators.
•

Appendix 4: Repair & Maintenance Procedures

Repair & maintenance procedures
All repairs to be carried out in accordance with FEM Code of Practice, using qualified & approved installers.
The successful repair company should verify the system type and exact component specification on site, prior
to ordering/replacing any components.
In house maintenance staff can be trained on our Rack Maintenance course to enable minor works to be
carried out.

Please contact us for more information.

Further Reading

Health & Safety Executive

• Warehouse and Storage: A guide to health and safety
(free download available: at http://www.hse.gov.uk/pubns/books/hsg76.htm)

16
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Appendix 5: Company Contact Details:

Company

Name: Linear Storage Solutions Ltd

Address: The Annexe

30 Christchurch Road
Bournemouth.
Dorset.
BH1 3PD

Telephone:
Office: 01202 538400

Email: sales@linearstorage.co.uk
Web: www.linearstorage.co.uk

17
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Pallet Racking Safety Awareness & Inspection Course

Storage racking should be properly maintained and in good order.

Rack safety inspections are required to prevent and minimise the effects of accidents, to comply with
the requirements of PUWER 1998 and to promote safety in the workplace.

Our half-day course will provide your staff with advice and guidance to enable them to carry out basic
rack inspections in accordance with FEM/HSE guidelines.

• Legal responsibilities
• Responsibilities – corporate and individual
• Damage assessment
• Causes and outcomes of damage
• Reduction/prevention of damage
• Cost effective by promoting in-house inspections.
• Legal compliance with the PUWER 1998 regulations
• The key components and roles of racking, shelving, and mezzanines
• Essential safe storage techniques
• What to look for when it comes to racking, damage, and safety hazards
• The importance of load signs
• Key methods to prevent damage to racking, shelving and mezzanines
• Effective reporting procedures

18
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Pallet Racking Safety Awareness Course
The days of simply carrying out a formal racking inspection once or twice or year just to meet your HSE
obligations are now seen as a reactive approach to warehouse management.

The ability of your employees to identify and report potential damage to racking, shelving and mezzanines
could not only save your company thousands in repairs but also protect the health and safety of your
employees.

Our Inspector has developed a practical, hands-on training programme to provide your warehouse operators
with the basic knowledge of safe storage techniques and ensure a safe working environment throughout the
year.

The course has been designed around the SEMA Inspectors Training course, each candidate will be authorised
and qualified to undertake internal inspections for the company they work for (NOT External Inspections).

The Key Benefits

From an operator’s perspective, your employees will be more aware of the potential hazards in their daily
working and gain confidence from being more in control of their safety.

The increased awareness of employees will result in a safer working environment, minimising your exposure
to risk and potential incidents. By identifying racking damage at the earliest possible stage, you will also
minimise the potential cost of rack repairs and damage to goods being stored.

On successfully completing this course, the candidates will be issued with a Certificate of Competency that is
valid for 5 years.

Please contact us if you would like a quotation for Training at your own facilities.

19
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk
 Date: Monday 4th April 2022 Ref: QU-8796 - Stark Industries
Outline Plan (Not to scale - Representative of Layout Only)

20
Linear Storage Solutions Ltd
The Annexe
30 Christchurch Road
Bournemouth. Dorset. BH1 3PD
Tel: 01202 538400
Email: sales@linearstorage.co.uk