How to Perform a Pallet Racking Inspection

In both Australia and New Zealand, AS 4084:2023 is the primary standard governing steel storage racking. New Zealand follows the Australian Standard for pallet racking to ensure safety and compliance, which means that organisations in both countries must keep their racking structures in good condition. Under WorkSafe health and safety legislation, racking is considered a structure that needs to be maintained to protect workers from potential hazards.

While AS 4084:2023 recommends annual independent inspections, a monthly internal inspection can help you catch issues early, reduce risks, and maintain a safer warehouse environment. Below is a step-by-step guide on conducting your own monthly racking inspection.

1. Before You Begin

• Plan inspections: Schedule an internal inspection every month, complementing your annual, independent review.
• Gather tools: Have a camera (for documentation), measuring tools (spirit level, tape measure), and personal protective equipment (PPE).
• Know your load ratings: Familiarize yourself with your racking configuration and its load-bearing limits.

2. Check for Overloading

• Look for deflection: Noticeable bowing in beams indicates overloading. Beam connectors at uprights should remain parallel.
• Inspect connectors: Deformation or a “V” shape in connectors signals past or ongoing overloading.
• Take action: If significant deformation is present, stop using the affected bay and consult a competent person to assess repairs or replacements.

3. Examine Beams and Welds for Damage

• Identify impacts: Look for dents, bends, or scrapes that may suggest forklift or pallet collisions.
• Check welds: Even minor collisions can cause weld cracks; if uncertain, seek evaluation by a competent person.
• Replace if needed: Severely damaged beams must be removed from service and replaced promptly.

4. Ensure Beam Connectors and Safety Clips Are Secure

• Verify presence: Ensure all beam connectors and safety clips are intact and installed correctly.
• Replace missing clips: Only use clips approved by the racking manufacturer. Frequent dislodging may require consulting the installer or manufacturer.
• Correct popped beams: A beam popped out of its upright is supported by only one connector—an immediate safety hazard.

5. Inspect Anchor Bolts and Ground Fixings

• Confirm tightness: Check that all anchor bolts are firmly secured. Retighten any loose bolts.
• Look for damage: Ensure floor fixings and footplates are not bent or broken. Each footplate requires at least two anchors.
• Address issues: Replace damaged bolts or fixings immediately according to the manufacturer’s specifications.

6. Check Rated Capacity and Signage

• Visibility: Load rating signs should be clear and prominently displayed.
• Accuracy: Confirm the racking configuration matches the details on load signs. Any changes require updated signage.
• Stay compliant: Damaged or missing signs should be replaced without delay to avoid confusion and ensure safety.

7. Examine Uprights and Footplates

• Spot damage: Check for twists, splits, dents, or cracks.
• Replace if compromised: Damaged uprights and footplates can reduce structural integrity and must be replaced promptly.

8. Confirm Racking is Plumb

• Measure vertical alignment: Use a spirit level or straight edge to check if uprights are within allowed tolerances.
• Identify causes: Misalignment may stem from incorrect installation, floor settling, or collisions with equipment.
• Consult experts: Contact your racking manufacturer or installer to correct significant misalignment.

9. Check Racking Braces

• Look for bends: Horizontal and diagonal braces can be damaged by impacts.
• Measure deviation: A deviation of over 10mm across a 1m length indicates serious damage.
• Replace as needed: Faulty braces must be replaced to maintain structural stability.

10. Record Findings and Take Action

• Document everything: Take notes and photos of any damage or concerns.
• Schedule repairs: Address minor issues promptly; major damage requires specialist advice.
• Maintain records: Keep inspection reports for compliance and for reference during annual independent audits.

Further Information and Resources

• Working safely with pallet racking systems.
• Stacking and shelving to withstand earthquakes.
• Forklift training.

Organise an Annual Inspection

An annual racking inspection by a qualified external provider is legally required to keep your warehouse fully compliant. Even with your regular monthly checks, it’s vital to have a professional inspection at least once a year to ensure every detail is up to code. Fill out the form below, and we’ll be in touch to schedule your Annual Pallet Racking Inspection—keeping your operations safe, efficient, and compliant.