Splicing Pallet Racking Frames – What the Standards Say

From time to time, warehouse operators come across pallet racking frames that have been spliced together — usually to extend the height of an upright without replacing it. While this might look like a clever way to reuse materials or make adjustments, it is generally not compliant with Australian Standards and can create serious safety risks.

What is Splicing?

Splicing is when two pieces of racking upright are joined together (usually with plates, bolts, or welding) to form a taller frame. This is often done on-site as a cost-saving measure instead of ordering the correct height frames from the manufacturer.

Why Splicing is a Problem

Pallet racking frames are carefully designed and tested as a complete unit by the manufacturer. The upright profile, bracing pattern, and welds are engineered to distribute loads evenly and safely.

When frames are spliced:

• The original testing and certification are invalid.

• Weak points are introduced at the splice connection.

• The upright may no longer perform as intended under load.

This is especially dangerous at higher elevations, where the splice is under additional bending stress.

Australian Standards on Splicing

The current AS 4084-2023 Steel Storage Racking standard makes it clear:

• Uprights and frames must be used as designed and supplied by the manufacturer.

• Modifications (including splicing) that change the performance of the upright are not permitted unless they have been tested and certified by the original manufacturer.

• Any frame found to be spliced without manufacturer approval is considered non-compliant and must be replaced.

In practice, this means splicing is only acceptable if it is a factory-approved solution designed, tested, and supplied by the racking manufacturer. On-site or makeshift splicing is not allowed under the standard.

Inspection Findings

When carrying out inspections, spliced frames are treated as a red risk (very serious damage) because they cannot be guaranteed safe or compliant. The only corrective action is to replace the spliced frame with the correct, factory-supplied upright.

Final Thoughts

Splicing frames may look like a way to save money, but it introduces a major safety hazard and puts your warehouse out of compliance. According to AS 4084-2023, frames must be used as manufactured and certified — no exceptions. If you come across spliced frames, the safest and only option is replacement.