Common Issues Found During a Pallet Racking Inspection

As part of our commitment to warehouse safety and compliance with AS 4084:2023, here are the real-world issues we uncover most often during inspections. These are not hypothetical—these are the very problems we consistently document and address:

1. Damaged Uprights and Frames

Look for dents, bends, twists, or buckling in the vertical frames—especially on the front face. Even minor deformations can exceed safety thresholds and risk non-compliance. These typically result from forklift impacts or improper loading.

2. Missing or Damaged Beam Safety Clips

Safety clips (or beam locks) keep the beams securely in place. Missing, bent, or incorrectly installed clips jeopardise stability and are a common compliance failure under AS 4084.

3. Overloaded or Improperly Loaded Racking

Exceeding load capacities—or loading pallets incorrectly—can place excessive stress on beams and frames, raising collapse risks. Visible, accurate load signage is required to prevent this.

4. Missing or Incorrect Load Signage

Every rack must display clear, correct signage: maximum unit load, bay load, and beam capacity must match the actual system configuration. Outdated, incorrect, or missing signage directly breaches AS 4084.

5. Unanchored Baseplates and Floor Damage

Uprights need secure floor anchoring. Loose or missing anchor bolts, damaged baseplates or slabs greatly reduce stability and invalidate compliance.

6. Blocked Access or Poor Housekeeping

Cluttered aisles, debris around baseplates, or blocked bays not only hamper safe movement but can prevent parts of the system from being properly inspected—possibly leaving hazards unchecked.

7. Unapproved Modifications

Using mismatched components, DIY repairs, or modifications without supplier approval undermines structural integrity and breaches compliance. All components should be original and approved.

8. Missing or Outdated Technical Drawings

Without accurate, current technical or design drawings, it’s impossible to confirm the racking matches its certified design—hindering full compliance verification.

9. No Regular Inspections or Record-Keeping

AS 4084:2023 mandates formal inspections at least every 12 months, and more frequently (every 3–6 months) in high-traffic environments. Informal inspections (in-house checks) must also be documented. Failure to inspect or keep records not only risks safety—it exposes your business to liability.

Why These Issues Are Critical...

Even seemingly small problems—like a missing clip or a dented upright—can escalate into major safety hazards, costly downtime, or serious legal implications. Regular, professional inspections help you stay safe, compliant, and proactive.

With Pallet Racking Inspections, you're not just ticking a box. We:

• Identify real and often hidden safety risks

• Ensure your system aligns with AS 4084:2023

• Provide actionable reports and practical recommendations

• Help you avoid costly disruptions and liabilities