How Often Should Pallet Racking Be Inspected? A Practical Guide to AS 4084 Compliance

If you operate pallet racking in Australia, pallet racking safety standards aren’t optional – they’re part of your legal duty of care. AS 4084 sets out clear expectations for safe warehouse storage, compliant warehouse racking and ongoing inspections, but the “how often” and “what exactly do we check?” can still feel vague.

This guide breaks down inspection frequencies, what AS 4084 is really asking for, and how to turn that into a simple pallet racking safety audit checklist your team can follow.

Why pallet racking inspections matter

Racking is a structural system. When it’s damaged, overloaded or incorrectly modified, you’re dealing with a potential collapse – not just a bit of bent steel.

Regular pallet racking safety inspections help you:

• Catch impact damage early (before it turns into a red-tag situation)

• Confirm your pallet racking load ratings still match how the rack is being used

• Pick up unapproved changes – extra levels, different beams, or mixed brands

• Demonstrate due diligence under Australian pallet racking safety standards

In short: inspections are your first line of defence against unplanned downtime, damaged stock and serious injuries.

What AS 4084 expects from warehouse operators

AS 4084 is the core pallet racking safety standard in Australia. In plain language, it expects you to:

• Install racking in accordance with the manufacturer’s instructions and the standard

• Provide and maintain load signs that show the correct pallet racking load ratings

• Inspect racking regularly, by both in-house staff and a “competent person”

• Repair, unload or isolate any damaged or non-compliant racking without delay

The standard doesn’t run your warehouse day-to-day – but it does set the minimum expectations for compliant warehouse racking.

How often should pallet racking be inspected?

Think of inspections as three layers of protection: daily, routine and formal.

1. Daily / shift-level checks (operators)

Who: Forklift drivers, pickers, storepersons
How often: Every shift, as part of pre-start and walk-throughs

They’re not doing a technical audit – just watching for obvious issues, such as:

• Fresh impact damage to uprights, bracing or end frames

• Missing or dislodged beams, safety clips or boards

• Pallets overhanging beams excessively or sitting crooked

• Visible deflection that doesn’t spring back when unloaded

Train your operators to treat this like any other safety pre-start check on their equipment.

2. Routine internal inspections (supervisors)

Who: Warehouse supervisor or trained safety representative
How often: Typically monthly or quarterly, depending on traffic and risk

This is where a structured pallet racking safety audit checklist comes in. Your internal inspections should cover:

• Upright and bracing damage (recorded as green / amber / red where possible)

• Beam damage, deformation and missing safety clips

• Condition and presence of pallet racking safety barriers / protection

• Frame plumb and level (leaning, twisting, settlement)

• Housekeeping – pallet condition, debris, safe access to aisles

• Confirming load signs are current and legible

These inspections create a paper trail that you’re monitoring and managing risk, not just reacting when something goes wrong.

3. Formal expert inspections (competent person)

Who: External specialist or in-house engineer/technician deemed “competent”
How often: At intervals not exceeding 12 months, and also:

• After any significant impact

• After modifications, relocations or reconfigurations

A formal pallet racking safety inspection takes a deeper look at:

• Overall configuration versus original design and pallet racking load ratings

• Changes in beam levels, bay widths or pallet types

• Compatibility of components (including any mixed brands)

• Anchor fixings, base plates and floor condition

• Adequacy and placement of pallet racking safety barriers / protection

The outcome should be a written report with photos, risk categories and recommended actions.

What should be on your pallet racking audit checklist?

Every site is different, but a practical checklist for pallet racking systems will usually include:

1. Identification

   • Racking brand and type

   • Bay and aisle numbering

   • Load signs present and correct for each configuration

2. Damage and deformation

   • Uprights and bracing (dents, twists, corrosion)

   • Beams (deflection, end connector damage)

   • Mesh decks, boards, supports

3. Stability and fixings

   • Correct anchors in all base plates

   • No missing bolts, nuts or locking devices

   • No signs of slab cracking or movement around footplates

4. Protection and environment

   • Column guards, end barriers and guard rails in place

   • Impact points protected at cross-aisles and intersections

   • Exposure to moisture, chemicals or corrosive environments considered

5. Usage and loading

   • Pallet types match the design (e.g. CHEP vs one-way pallets)

   • No ad-hoc storage of loose items on beams

   • No stored loads exceeding the specified pallet racking load ratings

This checklist forms the backbone of your pallet racking safety audit and can be adapted for different warehouses – from small commercial stores through to large industrial facilities.

How inspections tie into other safety controls

Inspections don’t stand alone. They need to be supported by:

• Operator training – so staff understand how racking works and what damage looks like

• Clear reporting lines – everyone knows who to tell and what to do if damage is found

• Maintenance and repairs – damaged components are repaired or replaced promptly

• Good warehouse layout design – with appropriate aisle widths, traffic flows and signage

Often, a formal audit will identify where additional pallet racking safety barriers / protection should be installed – for example at ends of high-traffic aisles or near doorways.

When should you call in a specialist?

Bring in a pallet racking inspection specialist when:

• You haven’t had a formal inspection in the last 12 months

• There’s been a significant forklift impact or near-miss

• You’re changing your layout, increasing beam levels or adding pallet positions

• You’ve inherited existing racking and aren’t sure about its history or capacity

If you’re operating warehouse racking in Australia and New Zealand, an external inspection is often the fastest way to close any gaps in AS 4084 pallet racking compliance.

How Better Storage Systems can help

Better Storage Systems provides end-to-end support for pallet racking systems – from pallet racking design and quote through to installation, repairs and scheduled safety audits.

We can:

• Conduct formal inspections in line with Australian pallet racking safety standards

• Provide a clear, prioritised list of repairs (green / amber / red)

• Update load signage to reflect the correct pallet racking load ratings

• Recommend and install appropriate pallet racking safety barriers / protection

• Help you plan for future growth with safe, compliant warehouse storage solutions

If it’s been a while since your last inspection – or you’re unsure whether your current racking is compliant – now is the time to act.

Book a pallet racking safety inspection today and make sure your warehouse racking is safe, compliant and ready for growth.