Understanding the Traffic Light Classification System in Pallet Racking Inspections

When pallet racking inspections are carried out in Australia, the findings are categorised using a traffic light classification system as outlined in AS 4084-2023 Steel Storage Racking. This standard provides clear guidance on how to assess damage and what action to take, ensuring consistency and compliance across all inspections.

Green – Safe to Use

Standard reference: Classified as “Category 3 – Serviceable.”

This means the damaged to the racking minor and racking is safe and compliant. No immediate action is required other than to monitor the damage and continuing normal use and maintaining the regular inspection schedule.

Amber – Hazard, Repair Required Soon

Standard reference: Classified as “Category 2 – Hazardous Damage.”

Amber indicates damage that exceeds the acceptable limits of the standard but does not require immediate off-loading. The racking can still be used in the short term; however, repairs or replacement must be scheduled as soon as possible, typically within four weeks. If the repair cannot be completed in this timeframe, the racking should be off-loaded until corrective work is carried out.

Red – Unsafe, Immediate Action Required

Standard reference: Classified as “Category 1 – Very Serious Damage.”

Red is the most critical classification. It means the racking is unsafe to use, and the affected area must be immediately off-loaded, isolated, and repaired or replaced before being returned to service. Continuing to use racking in this condition presents an unacceptable risk of collapse or serious incident.

Why This Matters

The traffic light system in AS 4084-2023 is designed to make inspection results simple and clear for warehouse operators. By following this system, you know exactly what action to take:

• Green → Safe to keep using.

• Amber → Schedule prompt repairs.

• Red → Stop use immediately and fix before reloading.

Using this approach not only ensures compliance with Australian Standards but also helps keep both people and stock safe.