Pallet racking is the backbone of many warehouse storage systems. But damage, overloading, or poor packing can turn it into a safety risk. Regular inspections keep storage systems secure, reduce the chance of costly accidents, and help meet Australian standards.
So, what exactly gets checked during a pallet racking inspection?
Benefits of regular pallet racking inspections
Pallet racking inspections deliver critical benefits beyond compliance. A formal inspection prevents workplace injuries and accidents, often caused by seemingly small issues like bent beams or loose components that go unnoticed.
Beyond these immediate concerns, conducting regular racking audits ensures you meet standards, avoid regulatory fines, and maintain proof of compliance for insurance purposes. Many insurers require documented pallet racking inspection records to validate claims. Without this documentation, insurers may reject coverage after a warehouse incident.
Additionally, investing in preventive inspection is far more cost-effective than emergency repairs. A single pallet racking collapse can cost tens of thousands in unplanned downtime, liability claims, and business interruption, making regular inspections one of the best risk management decisions a warehouse can make.
What is checked during a pallet racking inspection?
A pallet racking inspection is a detailed safety check of the entire racking system conducted by a competent person. It ensures compliance with the AS4084-2023 Australian Standard for steel storage racking, reduces workplace risks, and extends the life of your storage system. During a warehouse racking inspection, the inspector reviews every component to identify damage, poor installation, or overloading.
Uprights and frames
Inspectors check for dents, twists, corrosion, or leaning uprights. Plumb racking, where uprights are out of vertical alignment, is usually caused by forklift impact, which compromises structural integrity. Any damage to the pallet racking must be logged in the inspection report and repaired promptly. A damaged upright cannot safely support the designed load.
Beams and connections
Beams are inspected for bending, cracks, or concentrated loads on racking beams. Loose clips or welding defects indicate the racking is unsafe. Overloaded racking beams can cause collapse if not corrected. Inspectors also verify that beam connectors are secure and that connections meet manufacturer specifications. Beam deflection beyond acceptable limits is a red flag for overloading or structural failure risk.
Base plates and floor fixings
Anchors and base plates secure the steel storage racking to the warehouse floor. Inspectors look for loose bolts, damaged plates, or cracks that threaten the stability of the pallet racking system. Weakened floor fixings are a major safety hazard because they prevent the entire racking structure from staying plumb and secure.
Load signs and capacity labels
Safe working load signs must be approved by the racking manufacturer and clearly displayed at each racking level. Inspectors confirm signs are visible, accurate, and compliant with the Australian standard for steel storage racking. Missing or faded labels create confusion about safe weight limits and increase the risk of overloading.
Pallets in use
Damaged pallets, uneven loads, or pallets overhanging the pallet racking beams create risks. Inspectors also check whether the racking design or components overlap pallets, which can cause overloaded racking and health and safety risks. Overhanging loads shift weight distribution and can trigger beam failure.
Aisle clearance and access
Clear aisles and safe access at the back of the racking are essential for warehouse safety. Inspectors confirm there is enough space for forklifts and other material handling equipment used for picking. Blocked access points increase the chance of collisions with uprights and damage to the pallet racking, which then compromises the structural system.
Environmental conditions
Exposure to water, chemicals, or heat weakens steel storage racking over time. Inspectors look for rust, corrosion, and damaged beams. Ongoing maintenance of the racking should address these risks to ensure the safety of your staff and the longevity of your storage system.
Frequency and scheduling of warehouse racking inspections
Regular inspections are essential to keep pallet racking safe, stable, and compliant. They help catch problems early, prevent costly damage, and protect staff working around the racking system. Here are the key times when a pallet racking inspection should be carried out:
- Daily checks - warehouse staff inspect for visible damage, leaning uprights, or pallets overhanging the pallet racking.
- Regular inspections - a competent person performs a formal rack inspection every 12 months. Under AS4084-2023, this is a minimum requirement, though many businesses conduct quarterly inspections for systems under heavy, continuous use.
- After damage - inspections must follow forklift collisions, damaged beams, or loose components.
- After modifications - required when welding, adding cleats, or changing clips not approved by the manufacturer. Never adjust beam levels or make design changes without consulting the racking manufacturer.
- Best practice - keep an inspection schedule, use independent pallet racking inspectors, and record all results in an inspection report.
Thorough documentation, trained personnel, and a consistent schedule all contribute to a safer and regulation-compliant warehouse.
DIY checks vs. professional pallet racking inspections
Informal visual checks by warehouse staff are recommended daily and serve as an early warning system. However, informal checks do not count as an official pallet racking inspection under AS4084-2023.
To remain compliant with Australian standards, all operational pallet racking must be independently inspected by a competent person at least once per year. A professional inspector brings formal training, industry experience, and knowledge of requirements. They are the only party qualified to assess structural integrity, identify compliance issues, and provide credible reports for audits and insurance purposes.
While some warehouse managers may be highly competent at their role, they may not understand the full engineering of a racking system or be able to determine differences between brands or types of damage. Professional pallet racking inspection services offer objective, expert assessment and documented compliance proof.
How to choose a qualified inspector for your racking audits
To choose a qualified inspector for your pallet racking inspections, look for someone with formal training, industry experience, and strong knowledge of AS4084-2023. They should be able to assess risks, spot compliance issues, and provide clear reports.
Importantly, only the racking manufacturer can provide weight loadings on the racking system. Third-party inspectors who claim to certify weight limits are not meeting the standard requirements and may put your warehouse at legal risk.
Before hiring, ask about their certifications, past warehouse racking inspections, and how they stay updated with Australian standards. Request references from recent clients and review sample inspection reports.
Third-party audits from certified professionals add value by ensuring unbiased, credible assessments that regulators will accept Certified independent inspectors are more likely to follow standard procedures and produce reliable reports for audits and insurance purposes.
What to expect from a racking inspection report
A comprehensive pallet racking inspection report should include:
- Identification of racking system - location, racking type (selective, push-back, etc.), age
- Visual inspection findings - damage observations, photographic evidence, specific locations
- Structural assessment - uprights, beams, connections, deflection measurements, alignment
- Load capacity verification - confirmation of safe working load signs, compliance with manufacturer specifications
- Damage classification - color-coded severity levels (green/amber/red) for urgency
- Compliance status - confirmation of AS4084-2023 compliance or areas of non-compliance
- Repair recommendations - specific action items with priority levels
- Certification - inspector signature, certification details, valid date
- Follow-up actions - suggested timeline for repairs and next inspection date
Detailed reports create the documentation trail required for insurance validation and regulatory compliance.
Frequently asked questions
Can I conduct the inspection myself?
You may conduct informal daily visual checks to spot obvious damage or hazards. However, formal pallet racking inspections required under AS4084-2023 must be conducted by a competent person, typically an independent professional or the racking manufacturer.
What is the difference between a racking audit and a racking inspection?
A pallet racking inspection is the formal assessment required by AS4084-2023 at least once every 12 months. A racking audit typically refers to a comprehensive review, often conducted by independent professionals or manufacturers, that may include inspections plus broader operational assessments of how the racking is being used and maintained.
What happens if I don't conduct regular inspections?
Failure to conduct regular pallet racking inspections can result in regulatory fines, workplace shutdowns by health and safety authorities, rejected insurance claims after incidents, and serious safety risks to staff. A seemingly small issue like a bent beam can escalate into a catastrophic collapse if left unaddressed. Preventive inspection is far less costly than emergency repairs, liability claims, or business interruption.