Common Racking Issues You Shouldn’t Ignore

 

Pallet racking systems play a critical role in warehouse safety and efficiency. Even seemingly minor damage or wear can quickly lead to major risks. Regular inspections ensure your system remains compliant with AS 4084:2023, safe for your team, and structurally sound.

Below are some of the most common issues we find during inspections. While every site is different, these are typical warning signs that should never be ignored.

​

Damaged Uprights and Frames

​

Look out for dents, bends, twists, or buckling in the vertical frames. According to Australian Standards, even small deformations — particularly on the front face — can exceed safety limits and render the system non-compliant. Damage often occurs from forklift impacts or poor loading practices and must be assessed immediately.

​

Missing or Damaged Beam Safety Clips

​

Safety clips secure beams in place and prevent them from dislodging under load or impact. Missing, bent, or incorrectly installed clips compromise the stability of the entire structure and are a common compliance failure under AS 4084.

​

Overloaded or Improperly Loaded Racking

​

Pallet racking must be loaded according to specified capacities. Overloading or storing items incorrectly can lead to excessive stress on beams and frames, increasing the risk of collapse. Australian Standards also require load signage to be visible and accurate, reflecting the specific racking system in place.

​

Missing  or  Incorrect  Load  Signage

 

All racking must have clearly visible and correct load signage in place, in line with the system's certified design. Signs must show the maximum unit load, bay load, and beam capacity. Incorrect, outdated, or missing signage is a direct breach of AS 4084 and can result in unsafe practices or overloading. Every racking configuration must have signage that matches its specific layout and structure.

​

Unanchored Baseplates and Floor Damage

​

All uprights must be securely anchored to the floor as per AS 4084 requirements. Loose bolts, missing anchors, or damage to the slab can destabilise the system and invalidate compliance. Anchoring ensures the racking remains in position during normal use and accidental impact.

​

Blocked Access or Poor Housekeeping

​

Blocked bays, cluttered aisles, or debris around baseplates prevent proper inspection and safe access. Racking that cannot be fully inspected due to poor housekeeping may not be included in your inspection report, potentially leaving hazards unchecked.

​

Unapproved Modifications

​

Combining components from different brands, performing DIY repairs, or modifying the system without supplier approval violates compliance and can compromise structural integrity. All racking systems must be installed and maintained using approved parts and configurations.

​

Missing or Outdated Technical Drawings

​

Current technical drawings are essential for verifying that your racking matches its certified design. Drawings must be available during inspections to confirm details like layout, load ratings, and anchoring. Without them, full compliance cannot be assessed or confirmed.

​

No Regular Inspections or Record-Keeping

​

AS 4084:2023 requires that pallet racking undergoes formal inspections at least every 12 months, and in high-traffic or high-use environments, inspections should be conducted every 3 to 6 months. In addition to these formal checks, regular informal (in-house) inspections should be carried out and documented. Failing to inspect or maintain proper records of inspections and repairs not only puts your team at risk but may also expose your business to liability in the event of an incident. A complete inspection history helps track ongoing issues, plan maintenance, and prove due diligence.

​

Stay Safe and Compliant...

​

These issues are common but serious — and that’s why our inspections go beyond a surface check. We provide detailed, standards-based assessments to help you maintain a safe, efficient, and compliant warehouse.

Want to learn more about what’s involved in a professional racking inspection?
[View Full Inspection Process] or [Book Now]