Correctly Completing a Pallet Racking Load Sign

Pallet Racking load signs are a mandatory requirement under AS 4084-2023 Steel Storage Racking. They serve as the official reference for the safe working limits of each racking installation and must be displayed in a visible position on every racking structure. The accuracy of these signs is essential for maintaining compliance, protecting staff, and preventing overloading that could lead to structural failure.

The following explains how each field on a pallet racking load sign must be completed:

Beam Profile

The beam profile must be specified to correctly identify the load-carrying member. This detail should be taken directly from the supplier’s technical documentation, as load capacities vary according to beam dimensions, steel grade, and manufacturing tolerances.

Maximum Pallet Load

This figure indicates the maximum unit load (per pallet) that the system can safely support. It must be determined using the supplier’s certified load ratings and should not be estimated. Operators must never exceed this limit for any single pallet stored in the racking.

Maximum Level Load

This is the maximum total load that can be placed on a single beam level (all pallets combined). Entering the correct value ensures that the combined effect of pallet loads does not exceed the beam pair’s design capacity.

Maximum Bay Load

The maximum bay load is the total allowable load across the full height of one racking bay, incorporating all beam levels. This figure must align with the supplier’s data, as exceeding bay capacity can cause frame overstress and increase the risk of collapse.

Beam Heights (First Beam and Second Beam)

The load rating of pallet racking is dependent on the spacing between beam levels. The first beam height (measured from the finished floor to the underside of the first beam) and the distance to the second beam must be recorded precisely. Incorrectly stating these values may result in a load sign that does not reflect the actual structural performance of the system.

Supplier Information

The supplier’s name, reference number, and contact information must be recorded. This provides traceability and ensures that operators and inspectors can refer back to the original load calculations if required.

Installer Information

The installation date and the details of the installing party must be entered. This information assists with audit trails, inspection scheduling, and warranty considerations.

Importance of Accurate Completion

Under AS 4084, pallet racking load signs are not optional—they are a compliance requirement. Furthermore, they must be updated whenever changes are made to the racking configuration (for example, beam levels being relocated). Using incorrect or incomplete information on a load si

gn compromises both safety and compliance.

Routine inspections, carried out by a qualified racking inspector, should verify that the load signs remain accurate and reflect the current condition and configuration of the racking system.

At Pallet Racking Inspections, we ensure that load signs are completed in accordance with Australian Standards and that all technical information is correct and verifiable. This guarantees that your racking remains compliant, safe, and fit for purpose.