Unapproved Modifications – Why DIY Fixes Put Your Racking at Risk

Pallet racking systems are carefully engineered structures, designed and tested to meet strict safety standards. But one of the most common and dangerous issues we uncover during inspections is unapproved modifications — changes made to the system without consulting the manufacturer or a qualified engineer.

While these adjustments might seem harmless or “practical,” they often compromise the entire system’s integrity and make the racking non-compliant with AS 4084:2023 (Steel Storage Racking).

What Counts as an Unapproved Modification?

Non-Compliant Wall Bracing

Unapproved modifications can include:

• Moving or re-positioning beams without updating the system design or load signage

• Drilling new holes into uprights or beams

• Welding, grinding, or cutting racking components

• Mixing and matching parts from different brands or suppliers

• Using makeshift repairs such as bolts, brackets, or straps in place of manufacturer-approved components

• Adding extra beam levels without recalculating the load capacities

Why They’re a Problem

Racking is designed as a complete system. When you change part of it without approval, you:

• Weaken the structure and increase the risk of collapse

• Make load ratings and signage inaccurate

• Void manufacturer warranties and compliance

• Put staff, stock, and equipment in danger

Even something as simple as moving a beam level can drastically reduce load capacity if it’s not properly assessed.

What the Standards Say

According to AS 4084:2023, all racking systems must be installed, used, and maintained in line with the manufacturer’s specifications. Any modification requires approval from either:

• The racking manufacturer, or

• A qualified structural engineer

DIY fixes or using parts from another brand are strictly non-compliant.

How to Stay Compliant

• Never alter your racking system without written approval from the supplier or a qualified engineer

• Use only original, manufacturer-approved components

• Update load signage immediately after any approved modification

• Book regular inspections to ensure compliance with AS 4084:2023

How We Can Help...

At Pallet Racking Inspections, we regularly identify unapproved modifications that businesses weren’t even aware of. Our reports highlight these risks and provide practical guidance on how to bring your racking back to compliance — whether that means replacing altered components or arranging for engineering approval.