Do It Once, Do It Right: Why Not All Pallet Racking Inspections Are the Same

There’s an old saying — “a poor man pays twice.” In the world of pallet racking, this couldn’t be more accurate.

We regularly carry out inspections on racking that has already been “inspected” by someone else, only to discover multiple non-compliant issues that were completely missed.

The unfortunate reality is that not all inspections are equal, and just because your racking has been looked at doesn’t automatically mean it’s safe or compliant.

The Problem with “Cheap and Quick” Inspections

There are plenty of people offering pallet racking inspections these days. Some do it properly — in line with AS 4084:2023 (Steel Storage Racking) — but many others don’t.

A proper inspection requires knowledge, experience, and time. It involves more than just a quick walk-through and a few photos. It means checking every beam, frame, baseplate, clip, brace, and anchor — against the tolerances and requirements set out in the Australian Standards.

Unfortunately, some inspectors take shortcuts. They may not have the proper training, or they may simply be focused on speed rather than accuracy. The end result?

• Damaged components missed completely.

• Incorrect or missing load signage not noted.

• Unsafe modifications ignored.

• Outdated or missing technical drawings overlooked.

It’s easy to hand over a report that looks official, but if it doesn’t meet the standard — or worse, if it misses serious damage — it’s not worth the paper it’s printed on.

The Cost of a Bad Inspection

When a poor-quality inspection misses a fault, it doesn’t make the racking any safer — it just hides the danger. The risk doesn’t go away, it simply becomes your problem when something goes wrong.

We’ve seen systems that had been “cleared” in reports despite having:

• Rusted or unanchored baseplates,

• Damaged or missing bracing,

• Severely bent uprights,

• Beams without safety clips,

• Incorrect spacing or load signage.

In several cases, these systems were serious safety hazards. Had they collapsed, the business owner — not the inspector — would have been held responsible.

Who’s Responsible?

This is the most important part: the responsibility always sits with the owner or operator of the racking.

Even if you’ve had a recent inspection, you can’t assume you’re in the clear unless it was done properly and by a qualified inspector. In the event of an accident or investigation, regulators and insurers will look for:

• A qualified inspection report carried out to AS 4084:2023,

• Records showing repairs were made,

• A valid Certificate of Compliance.

If your report doesn’t meet the required standard — or if the inspection was carried out incorrectly — you’re still liable.

What a Proper Inspection Includes

A compliant inspection should include:

• A thorough visual and measurement-based assessment of all racking components.

• Reference to tolerances and limits from AS 4084:2023.

• Clear identification of all damage using the traffic light classification system (Green, Amber, Red).

• Detailed notes and photographic evidence.

• A follow-up process for repair and re-certification if required.

It should never be rushed, and you should always receive a full report — not just a checklist.

“Do It Once, Do It Right”

When it comes to pallet racking inspections, the cheapest option often ends up being the most expensive in the long run. A poor inspection can give you a false sense of security and leave your staff and business exposed to serious risk.

The difference between a cheap inspection and a proper one isn’t just a few dollars — it’s the difference between knowing your warehouse is safe and just hoping it is.

At the end of the day, a proper inspection ensures your racking complies with Australian Standards, protects your people, and keeps your business covered legally and financially.

So when it’s time for your next inspection, remember:

✅ Do it once.

✅ Do it right.

✅ And rest easy knowing your warehouse is safe and compliant.