Pallet Racking Inspection Explained...

What’s Involved in a Pallet Racking Inspection?

At Pallet Racking Inspections, we don’t cut corners. A proper inspection is more than a walk-through — it’s a deep dive into your storage system’s safety, stability, and compliance with Australian Standard AS 4084:2023.

Whether it’s your first time getting an inspection or you're brushing up on what to expect, here’s a detailed look at how we do things — and why our inspections go far beyond a quick glance.

Thorough, On-the-Ground Inspections

Our team walks every aisle and physically checks every component we can access. If it supports your pallets, connects to your beams, or anchors into the floor — we’re inspecting it. We also assess the way your racking is used and maintained.

Here’s a full breakdown of the areas we inspect, with real-world examples of what we’re looking for. These are just examples — damage or issues may be more minor or more serious depending on your racking system and usage.

1. Uprights & Frames

We inspect each upright (vertical post) for physical damage and alignment. Uprights are structural elements, and even small issues can cause major risks over time.

Example:
In a recent inspection, we found a front upright near a high-traffic aisle that had a visible dent around 250mm from the floor. The dent measured approximately 6mm of horizontal displacement across a 1.2m upright section. According to AS 4084, any deviation over 3mm across 1 metre is considered a critical defect, requiring immediate unloading and repair.

We also check for rust, corrosion, twisted frames, and missing bracing, especially in older warehouses or humid environments.

2. Beams & Beam Connectors

Beams are inspected for bending (deflection), misalignment, or damaged connectors. We also make sure all beams are properly secured with locking clips or safety pins.

Example:
One warehouse had a pair of 2591mm beams sagging (deflection) more than 20mm under load, significantly exceeding the L/200 limit outlined in the Standard. This was due to incorrect product storage (heavy pallets stored above rated capacity) and missing safety clips that allowed some beams to become partially dislodged. We recommended immediate offloading and replacement.

We also check that all beams are the correct type and are installed to manufacturer specifications.

3. Baseplates & Floor Anchoring

Each upright must be securely fixed to the floor with the correct number and type of anchor bolts, and baseplates must be undamaged and properly aligned.

Example:
In one facility, several baseplates were missing anchor bolts entirely, while others had bolts that were loose due to vibration from forklift traffic. These are compliance failures and need to be rectified to ensure structural integrity.

Even one unsecured upright can compromise the whole row in the event of a collision or uneven load.

4. Load Signage

AS 4084 requires that all racking be clearly labelled with accurate and visible Safe Working Load (SWL) signage.

Example:
We inspected a warehouse where new racking had been installed, but the old signage remained. It displayed outdated beam configurations and incorrect maximum loads, which could easily mislead staff. The signage also lacked the racking supplier’s name, date of install, and other critical information.

This is a compliance issue that’s easy to fix, but often overlooked. We check for location, visibility, accuracy, and required information on every load sign.

5. General Usage, Housekeeping & Access

Sometimes it’s not the racking itself, but how it’s being used or maintained that presents the biggest risk.

Example:
A site inspection revealed that pallets were being placed across multiple beam levels at odd angles to “fit more stock.” This led to uneven loads, overhanging pallets, and a bent front upright caused by a bump from a poorly stacked pallet. In another case, entire aisles were blocked with stock and packaging, preventing us from inspecting the full system. Areas like these are noted as "not inspected" in the report until they can be cleared.

We also look for things like unauthorised attachments (e.g., chains or boards), racking that has been modified without engineer approval, or pallet types that aren’t suitable for the racking design.

We Also Check For:

Previous damage that has not been reported or repaired
Incorrect beam levels or uneven spacing
Incompatible components from multiple racking brands
Racking placed too close to walls or building columns
Signs of impacts (e.g., scrape marks or flaking paint) that may indicate deeper issues

These items may seem small individually, but together they can compromise the performance of your entire storage system.

Comprehensive, Practical Reporting

After your inspection, we provide you with a full report that includes:

A list of all issues, clearly categorised by severity
Inspection photos of damage or non-compliance
Alert details relating to AS 4084:2023
Plain-English explanations and action steps
Colour-coded risk levels
Certificate of compliance if not work is required

We aim to make our reports easy to read and easy to act on. No confusing jargon — just practical safety guidance you can trust.

Risk Categories Explained

Our reporting follows the AS 4084 colour-coded rating system:

Red: High-risk issue. Immediate unloading and repair required.
Amber: Moderate issue. Safe to use for now but must be repaired soon.
Green: No defects. Racking is compliant.
Grey: Area was blocked or inaccessible at the time of inspection.

If areas are inaccessible due to stock or mess, we’ll mark them for reinspection later once they’ve been cleared. (Re-inspection fees apply)

Inspection Duration: How Long Will It Take?

The time required depends on your site size, the condition of your racking, and how easy it is to access. We will be in and out as quick as we can so as to not disrupt your workflow. Notes will be taken during the inspection and then we will do up the report off-site (in our office)

As a general guide:

A small warehouse might take 1 to 2 hours on site.
A medium-sized site can take 2 to 6 hours.
A large, complex site may take a day or more

We’ll always give you a time estimate up front, and we’ll let you know if anything on-site is causing delays (like blocked aisles or access issues).

How Often Should You Get an Inspection?

The minimum requirement under AS 4084 is every 12 months, but many businesses choose more frequent inspections — especially in high-traffic or high-risk areas.

12 months – Minimum required for general use
Every 6 months – Common for busy warehouses with multiple shifts
Every 3 months – Recommended for high-volume forklift traffic, narrow aisles, or cold storage facilities
After any impact – Any time a forklift strikes the racking, it must be re-inspected before being used again

Regular inspections don’t just help with compliance — they prevent injuries, product damage, and unnecessary downtime.

What If We Find Damage?

If we identify any red or amber risk items, we’ll provide specific repair details. We can also help coordinate repairs with trusted technicians or help you source components through our supply partners.

You’ll require a follow-up inspection once repairs are made, ensuring your system is safe and certifiable again.

Certified, Experienced, and Here to Help

All inspections are carried out by industry-experienced professionals with in-depth knowledge of racking systems, installation methods, and Australian Standards. We’re not just trained — we’ve been on the tools, in the warehouses, and in the meetings where safety really matters.

We aim to build long-term relationships, not one-time transactions.

Book Your Inspection Today

Ready to make sure your racking is compliant, safe, and ready for certification?

Contact us now to book an inspection, ask a question, or just have a chat about what you need. We’re here to help. (Contact Details)