Warehouse automation solves labor constraints—not liability. Automated storage and retrieval systems (ASRS) are steel structures under load, subject to OSHA regulations, ANSI/MHI rack standards, and the same physics as traditional pallet racking. Automation doesn’t reduce risk; it increases the consequences of failure.
This guide explains what OSHA and MHI require, what makes ASRS racking uniquely demanding, and how to build an inspection program that protects uptime, employees, and your investment.
Automated storage and retrieval systems (ASRS) are computer-controlled solutions that automatically store and retrieve inventory with minimal human intervention. These systems pair engineered rack structures with cranes, shuttles, conveyors, and advanced warehouse software to maximize space and throughput.
| ASRS Type | Typical Load Type | Ideal Use Case | Storage Height | Key Advantages |
|---|---|---|---|---|
| Unit-Load ASRS | Pallets (1,000+ lb) | High-bay pallet storage | 60–100+ ft | High-density, automated pallet handling |
| Mini-Load ASRS | Totes, trays, cartons | Small-item fulfillment | 20–60 ft | Fast picking, precise movement |
| Shuttle Systems | Totes & cartons | High-throughput order picking | Multi-level grid | Extremely fast, scalable |
| Vertical Lift Modules (VLMs) | Trays | Parts, tools, slow-medium movers | 15–40+ ft | Secure enclosed storage, saves floor space |
| Vertical Carousels | Shelves/carriers | Small parts & high-security items | 10–25 ft | Ergonomic access, compact footprint |
| Horizontal Carousels | Bins | High-speed picking of small SKUs | Low-medium height | Fast, compact, ideal for batching |
| Cube-Based (Robotic Grid) | Bins | Ultra-high density picking | Variable (grid height) | Highest density, flexible automation |
No. Automation reduces labor, but it does not eliminate structural risk. ASRS racks must remain stable, plumb, anchored, and capable of supporting the designated loads. These systems operate at height, with tight tolerances, and any deformation or misalignment can immediately affect safety, throughput, and equipment performance.
OSHA does not exempt automated facilities from safe storage, safe access, or lockout/tagout requirements. ANSI MH16.1 explicitly includes ASRS (“stacker racks”) and assigns owners responsibilities for inspection, repair, load plaques, and compliance.
Automation improves performance—but it doesn’t replace inspection and maintenance.
OSHA’s safety rules apply to all storage systems, including manual, semi-automated, and fully automated systems. There are no exemptions for ASRS equipment.
| Violation Type | Standard | Penalty (2025) |
|---|---|---|
| Improper storage | 29 CFR § 1910.176 | $0–$16,550 per violation |
| Lack of inspection/maintenance | General Duty Clause | Up to $161,000 (repeated) |
| Inadequate training | General Duty Clause | $0–$16,550 per violation |
| Obstructed aisles | 29 CFR § 1910.176 | $0–$16,550 per violation |
OSHA’s interpretation letters confirm that automation does not change which standards apply. Employers must still inspect equipment, maintain safe storage conditions, and eliminate hazards—even if the system is fully automated.
ANSI MH16.1, published by MHI’s Rack Manufacturers Institute (RMI), is the primary rack standard in North America. Section 1.2 of MH16.1 explicitly includes automated storage and retrieval systems (“stacker racks”).
If your rack supports an ASRS, you still own the rack and all the responsibilities that come with it.
For power-operated vertical carousels and vertical lift modules (VLMs), MH24.2 covers installation, operation, maintenance, and hazard control.
Automated storage and retrieval systems rely on highly engineered structures, and when those structures fail, the consequences are amplified by the speed, height, and density of ASRS operations. Real-world incidents have shown that failures in automated racks can have severe consequences.
Critical load testing in a large automated warehouse resulted in a total rack failure, causing damage to both the structure and the building.
A major fire at a Canadian Tire facility utilizing a high-density robotic ASRS (Attabotics) resulted in extensive damage and ultimately contributed to the ASRS provider’s downturn.
Lesson: Automation amplifies both productivity and risk. Regular inspection is not optional.
ASRS racks require a structured, risk-based inspection program due to height, density, and tight tolerances.
| Condition | Recommended Frequency |
|---|---|
| All ASRS racks (minimum) | Annually, by a qualified professional |
| High-risk areas | Monthly |
| Medium-risk areas | Quarterly |
| Low-risk areas | Twice per year |
| After impact/seismic event | Immediately |
Core inspection categories—uprights, bracing, beam connections, pallet and load conditions, and load plaques—remain the same in any racking system. What changes in an ASRS warehouse are the level of precision required: tighter tolerances, more frequent checks, and far less room for error.
ASRS-Specific Priorities
A single misaligned rail or loose anchor can trigger emergency stops, equipment faults, or cascading damage.
Load Distribution Matters
Uneven loading accelerates wear and can cause misalignment, deformation, or structural failure. Balanced loads are crucial for the optimal performance of automated equipment.
ASRS systems pose an elevated fire risk due to their tightly packed storage and limited access.
NFPA standards emphasize the need to ensure that fire suppression systems can reach every level of a dense racking structure. Key considerations include:
Local authorities having jurisdiction (AHJs) often impose additional conditions, such as:
Pair fire checks with regular ASRS rack inspections to catch issues early.
Automation improves throughput, but inspection protects it. ASRS racking remains subject to physical damage, overloading, seismic forces, and fire risk, regardless of automation. OSHA and MHI/RMI both require owners to inspect, maintain, and document rack conditions for safe operation.
A strong ASRS safety program includes:
When backed by structured inspections, your ASRS investment becomes safer, more reliable, and more resilient.