Racking repair services

Why can’t rack repairs wait?

Neglecting damaged racks invites serious consequences. Industry data shows racking failures account for nearly 15% of warehouse accidents, often caused by visible damage that was never repaired. In Europe, the transport and storage sector has a higher rate of fatal accidents than most other industries, many of which are preventable.

EU-OSHA estimates that rack collapse incidents cost €36 billion annually. What starts as a bent column or loose baseplate can escalate quickly, increasing repair costs by up to 30% if left unresolved.

Beyond safety, delayed repairs can lead to:

• Product losses from collapsed inventory
• Operational downtime, impacting SLAs and logistics contracts
• Non-compliance with UNE-EN 15635 and local safety laws
• Rising CAPEX, as issues become structural failures

In 3PL-run or leased sites, visible racking damage can also affect audit outcomes and property value. Fast, expert repairs keep your operation stable, compliant, and investment-secure.

Is your warehouse showing these red flags?

Not all damage is dramatic, but even minor issues can lead to major consequences. Here are signs your racking needs attention:

• Bent uprights or twisted frames after impact
• Beam deflection that compromises load safety
• Loose baseplates or anchoring points
• Misaligned horizontal beams from overloading or shifting
• Protective barriers are missing or damaged
• Unusual creaks, tilts, or movements during loading

If you’re seeing any of the above, your racking isn’t just inefficient, it’s unsafe. We’ll help you resolve issues before they grow into costly emergencies.

How our racking repair process works

BECOSAN’s repair process restores your warehouse with precision, designed for logistics and property managers across Europe. With minimal disruption and full transparency, we restore operational safety while supporting your internal teams and maintenance cycles.

1. On-site diagnosis and risk grading
   We assess the damage using a red, amber, or green grading system, along with photo documentation, to help you understand the urgency and scope.
2. Detailed repair quote and flexible scheduling
   We provide a cost breakdown including labour, parts, and optional phased repairs. Our project managers plan work around your operational windows to ensure continued throughput.
3. Certified execution with quality materials
   All repairs are performed by SEIRS and SEMA-trained technicians, using compatible parts and adhering to UNE-EN 15635 and PUWER standards.
4. Post-repair validation and reporting
   After work is completed, we document the results and issue a compliance-ready report for audits, insurers, or internal tracking.

If needed, we can also implement temporary “make safe” measures within 24 hours to stabilise high-risk zones until full repairs are scheduled.

Types of repairs we offer and what they include

Each repair is executed using pre-engineered kits or site-specific solutions, ensuring compatibility with European safety standards, including UNE-EN 15635 and PUWER requirements. All works are performed by certified technicians using CE-compliant components and Grade 5 or higher hardware.

The table below outlines the core types of racking repairs we provide, including their typical application areas and key components used:

• Column Repair
  Localised upright damage from forklift impact or corner strikes
  Upright reinforcement sleeves, bolted footplates, deflectors, and seismic options
  High-traffic zones, routine collision areas
• Frame Repair – Single Leg
  Damage to one side of the racking frame
  Upright replacement with integrated bracing, Grade 5 hardware, optional V-nose guards
  Minor impact without full structural compromise
• Frame Repair – Double Leg
  Damage affecting both front and rear columns or the full bay structure
  Engineered double-leg frame with struts, bolted installation, upgraded footplates
  Full-bay structural failures or deep impact zones
• Beam & Horizontal Repair
  Bent, sagging, or misaligned beams
  Load-rated beam replacement, locking pins, deflection correction, load signage updates
  Overloaded bays, deflection due to fatigue or misuse
• Baseplate & Anchoring
  Shifting or loosened anchors, slab movement, or seismic shifts
  Re-anchoring with chemical/mechanical fasteners, plate replacements, and floor slab testing
  Compliance-critical zones, seismic areas
• Protection Upgrades
  Prevention of future damage during repair works
  Installation of guards, bumpers, end-of-aisle shields, and traffic pattern analysis
  Facilities with forklifts or fast-moving vehicles

Types of racking issues we address during repairs

At BECOSAN, our repair teams are trained to identify and resolve both visible and underlying structural problems before they escalate.

One of the most common issues is bent or twisted uprights, often the result of low-level forklift impacts. Even a slight deformation can weaken load-bearing capacity and threaten the entire bay. We also regularly address deflected or sagging beams, which typically indicate metal fatigue or overloading and require careful load assessment and replacement where needed.

Another high-risk fault is loose or missing baseplate fixings, which compromise the rack’s anchorage to the floor. Left unchecked, these failures increase the likelihood of structural movement, especially in seismic zones. We reinforce or replace them to restore full structural grounding.

Other frequently addressed problems include impact-damaged frames, which may not always show visible cracks but often conceal internal stress points, and damaged or missing safety accessories, such as aisle-end guards or upright protectors. Replacing these safeguards is essential for long-term durability and impact resistance in high-traffic areas.

Why BECOSAN is the right repair partner for your facility

When your racks are compromised, you need more than just a repair—you need a partner who understands the full scope of logistics operations. BECOSAN brings together technical excellence with logistical precision to deliver results you can trust.

Our strengths include:

• Single point of contact for communication and accountability
• Local partner alliance for fast response in the UK, Spain, Germany, and beyond
• In-house project management for scope clarity and execution control
• Turnkey repair solutions covering everything from assessment to certification
• Financial flexibility with staged payments and CAPEX planning
• Compliance-first execution with SEMA, PUWER, and UNE-EN 15635 alignment
• ROI-focused repair strategy that protects uptime and avoids emergency costs

We’re trusted by 3PL leaders, facility operators, and industrial landlords across Europe to deliver results that combine speed, quality, and assurance.

Get your racks repaired without delays

Damaged racking threatens more than just the structure—it affects people, processes, and profitability. At BECOSAN, our certified repair services bring your warehouse back to safe, stable operations with speed and precision.

Speak with a BECOSAN repair specialist and secure your site today.

Frequently asked questions