Moving or Reconfiguring Your Pallet Racking? Here’s What You Need to Check

Warehouses are busy, evolving environments. As businesses grow, product ranges shift, and storage needs change, it’s common to reconfigure or relocate pallet racking. Maybe you’re moving into a new building, changing your layout to improve workflow, or simply trying to fit more pallets into the same space.

While it might look like “just bolting steel together,” pallet racking is an engineered storage system designed to strict Australian Standards. If it’s not installed and inspected correctly after a move or reconfiguration, it can quickly become unsafe — putting staff, stock, and compliance at risk.

Here’s what you should always check when racking has been moved or reconfigured:

1. Correct Reassembly

Racking must be reassembled exactly as designed by the manufacturer. Every upright, brace, beam, and locking device plays a role in the system’s strength. Common mistakes we see include:

• Beams installed upside down or at the wrong level.

• Frames not fully bolted together.

• Missing or incorrectly installed safety clips.

Even small errors can lead to instability or reduce load capacity. Always ensure components go back together as originally intended — no cutting, drilling, or “making it fit.”

2. Baseplates and Anchors

One of the biggest changes in the standards over time is around anchoring. In the past, it was common to see just one anchor per baseplate. Under AS 4084-2023, all pallet racking uprights must have two anchors per baseplate to properly secure the system.

When racking is relocated, old anchors can’t simply be reused. The new floor may be different (thicker, thinner, or weaker concrete), so anchoring must be rechecked and done fresh every time.

3. Alignment and Levelling

Racking frames must be vertical, level, and square. If they lean, twist, or sit unevenly, loads won’t be evenly distributed. This increases stress on beams and uprights and can lead to premature failure. During reinstallation, proper levelling tools should always be used, and packers may be required to correct floor variations.

4. Clearances for Forklifts and Traffic

Reconfiguring racking often changes aisle widths. Get this wrong, and you either:

• Risk collisions if aisles are too narrow, or

• Waste valuable floor space if aisles are too wide.

As a rule of thumb, standard forklifts need around 3.7

to 4.0 metres of aisle clearance. Narrow-aisle trucks may need less, while reach trucks may need more. Always check your equipment’s turning circle and lifting height before finalising a layout.

5. Load Signage

Your load signs must reflect the current configuration of your racking — not how it was set up before. If you’ve changed beam levels, bay heights, or overall system layout, the safe working load (SWL) could be different. Outdated signs are not just unhelpful, they make your system non-compliant.

6. Damage During the Move

Disassembly and relocation is when racking is most at risk of damage. Uprights can get dented, braces bent, and beams twisted. A common mistake is reinstalling damaged components because they “don’t look too bad.” Even small bends or dents reduce strength and compliance. Always inspect components before reuse, and replace anything that shows signs of damage.

7. Fire Safety and Emergency Exits

When reconfiguring a layout, it’s not just about forklifts and pallets. You also need to make sure racking isn’t blocking fire exits, sprinklers, or emergency equipment. Fire services and workplace safety laws require clear access, and non-compliance can lead to fines or shutdowns.

8. Professional Inspection Before Use

Most importantly: any reconfigured or relocated racking must be inspected before it’s put back into service. Even if everything looks right, there may be compliance issues you can’t see without measuring, checking anchor pull-out strength, or calculating safe loads.

Australian Standards require a formal inspection at least every 12 months, but after a move or major reconfiguration, an inspection should be carried out straight away. This ensures your system is safe, compliant, and certified for use.

The Bottom Line

Relocating or reconfiguring pallet racking is common, but it’s not something to cut corners on. Incorrect reassembly, poor anchoring, or unnoticed damage can lead to unsafe racking, costly downtime, or even collapse.

By checking reassembly, anchoring, alignment, clearances, signage, and component condition — and following up with a professional inspection — you’ll keep your racking safe, compliant, and ready to handle your stock.

When in doubt, always call in the experts. It’s faster, safer, and in the long run, far cheaper than fixing the consequences of a bad installation.