Pallet racking is the backbone of many warehouses. 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?
Australian standards that guide pallet racking inspections
AS4084-2023 is the current Australian Standard for steel storage racking. It replaced earlier versions like AS4084-2012 to improve safety, design, and inspection guidelines.
The 2023 updates place a stronger focus on several key areas to enhance pallet racking safety. These include clearer and more consistent load capacity markings, stricter limits on beam deflection to prevent structural failure, increased inspection frequency to catch issues early, and improved risk control measures to reduce the likelihood of accidents.
What is checked during a pallet racking inspection?
A pallet racking inspection is a detailed safety check of the entire racking system. 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, a competent person reviews every component to identify damage, poor installation, or overloading.
Uprights and frames
Inspectors check for dents, twists, corrosion, or leaning uprights. Plumb racking is usually caused by forklift impact, which affects the structural integrity. Damage to the pallet racking must be logged in the inspection report and repaired promptly.
Beams and connections
Beams are inspected for bending, cracks, or concentrated loads on racking beams. Loose clips or other components indicate the racking is unsafe. Overloaded racking beams can cause collapse if not corrected.
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.
Load signs and capacity labels
Safe working load signs must be approved by the racking manufacturer and clearly displayed. Inspectors confirm signs are visible, accurate, and compliant with the australian standard for steel storage racking.
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.
Aisle clearance and access
Clear aisles and safe access at the back of the racking are essential. Inspectors confirm there is enough space for forklifts used for picking and other material handling equipment. Blocked access points increase the chance of collisions and damage to the pallet racking.
Environmental conditions
Exposure to water, chemicals, or heat weakens steel storage racking. Inspectors look for rust, corrosion, and damaged beams. Ongoing maintenance of the racking should address these risks to ensure the safety of your staff.
Why these checks matter
A pallet racking safety inspection must follow the AS4084-2023 Australian Standard. Regular pallet racking inspections ensure:
- Safety of your staff
- Compliance with current Australian standards
- Effective operation and maintenance of the racking system
- A clear safety inspection report for audits and insurance
- Early detection of health and safety risks in the warehouse
Skipping inspections or ignoring damaged beams places the warehouse at risk of costly repairs, legal penalties, and serious safety incidents. This is why regular racking inspection services are essential.
Frequency and scheduling of 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 (or more often in high-use warehouses).
- 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.
- 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.
How to choose a qualified inspector
To choose a qualified inspector, 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, actionable reports.
Before hiring, ask about their certifications, past inspections, and how they stay updated with Australian standards. Third-party audits add value by ensuring unbiased, credible assessments.
Certified independent inspectors are more likely to follow standard procedures and produce reliable reports for audits and insurance purposes.
Frequently asked questions
How often should pallet racking be inspected in Australian warehouses?
According to AS4084-2023, pallet racking must be formally inspected at least every 12 months. Informal visual checks should be carried out more regularly, especially in high-traffic or high-risk environments.
What makes a pallet racking inspection compliant with Australian standards?
A compliant inspection must be carried out by a competent person who understands AS4084-2023. It should include checks on structural integrity, load signage, damage, and proper installation, and be documented in an official report.
Why is pallet racking inspection important for insurance coverage?
Many insurers require proof of regular pallet racking inspections to validate claims. Without documentation showing compliance with Australian standards, insurance providers may reject coverage after a warehouse incident.