What to Expect During a Pallet Racking Inspection

An inspection of your pallet racking system is not just a safety routine—it’s a thorough review to ensure everything is safe, compliant, and operating as intended under AS 4084:2023 Steel Storage Racking. Here's what happens when we visit and what you should expect.

Thorough, On-the-Ground Inspection

• We walk each aisle and physically check every accessible component: uprights, beams, connectors, baseplates, anchors, safety signage, etc.

• We assess how your racking is used and maintained. Usage patterns matter: overloaded pallets, misuse, improper stacking, or blocked access all affect safety.

Inspecting the Uprights & Frames

• Look for physical damage: dents, twists, misalignments, rust or corrosion. Even a small dent or a slight horizontal displacement in an upright can be serious.

• Check frame bracing, whether any frames are missing bracing, or if any deformations exceed the tolerant limits under AS 4084.

• Check alignment: making sure uprights remain upright (plumb) and correctly positioned.

Beams & Beam Connectors

• Beams are checked for deflection (sagging), bending, or misalignment.

• Confirm that beam connectors are undamaged and properly seated.

• Ensure every beam has the proper locking pins or safety clips in place.

• Verify beam type, profile, size, and that installation matches manufacturer specifications.

Baseplates & Floor Anchoring

• Every upright must be secured to the floor with correct anchor bolts. We check that the number, type, and condition of anchors are correct.

• Baseplates must be undamaged, properly aligned, and flush to the floor. Loose or missing bolts or damaged plates are flagged immediately.

Load Signage

• Signs must clearly display the Safe Working Load (SWL) for a pallet, level loading, and the full bay.

• Signage must be visible, accurate, and reflect current configurations. Outdated or incorrect signage is a compliance issue.

• Check that supplier name, installer details, and installation date are included where required.

General Usage, Housekeeping & Access

• How pallets are stored matters: overhangs, uneven loading, or pallets placed at odd angles can stress racks.

• Check that aisles are clear and access is unobstructed—blocked aisles reduce the ability to inspect and maintain.

• Look for unauthorised modifications, attachments, or incompatible components used in the system.

Risk Categorisation & Reporting

• Every issue we find is categorised by severity: Green, Amber, or Red (as per AS 4084 risk ratings).

  • Red: High risk — immediate unloading & repair required.

  • Amber: Moderate risk — safe for now but must be repaired soon.

  • Green: Compliant, no significant defects.

• We also mark any areas that were inaccessible at the time of inspection (Grey), with a note to re-inspect when access is cleared.

Inspection Duration & What Determines Time

• Time depends on size of the site, condition of racks, how easy access is, and how well the site is prepared.

• Small warehouses usually take 1-2 hours. Medium sites might take 2-6 hours. Large or complex warehouses may need a full day or more.

Frequency & When to Get an Inspection

• Minimum requirement under AS 4084 is every 12 months.

• More frequent inspections (every 6 or even 3 months) are recommended for high-traffic, busy or harsher environments (e.g., cold storage, narrow aisles).

• After any impact (e.g. from a forklift striking racking), a re-inspection is required before the rack is used again.

What Happens If Damage Is Found

• We’ll provide a detailed, practical report that includes photographs, severities, and recommended repairs.

• You’ll get plain-English explanations, action steps, and a compliance certificate if no corrective work is needed.

• If issues require repair, we can help with sourcing parts or trusted technicians.

• After repairs are completed, a follow-up inspection may be required to verify compliance again.

Final Thoughts

When you schedule a pallet racking inspection with us, you're not just getting a check-up; you’re getting a safety assurance. Every component—from frame to beam to signage—gets examined. If anything is not right, you’ll know. That means fewer surprises, safer operations, and confidence that your racking system meets the standard.