Home › Inspection checklist
Pallet racking inspection checklist (AS 4084 guidance)
This is a plain-English summary of the inspection questions Australian regulators publish for pallet racking. It is a starting point for informal checks and for knowing what a formal inspection should cover, not a replacement for either.
What this is and is not. The checks below are summarised from public guidance by WorkSafe Victoria, SafeWork NSW, SafeWork SA. It is not the checklist in AS 4084.2:2023 itself, which is a paid document (Standards Australia), and it is not a formal inspection or legal advice. Regulators say a competent person should do the formal inspection at least every 12 months. Their guidance is written for standard selective racking; drive-in, push-back, cantilever and other types may need additional measures.
How often, and who
- Informal checks: frequent, with the interval set by the manufacturer or a competent person (WorkSafe Victoria gives "daily or weekly" as an example). Use simple gauges or measuring tools (WorkSafe Victoria).
- Formal inspection: by a competent person at intervals not exceeding 12 months, with a written report of observations and corrective actions (SafeWork NSW, WorkSafe Victoria). SafeWork SA says racking should be "inspected regularly" and points to AS 4084 for the detail (SafeWork SA).
- Height: WorkSafe Victoria says racking over 8 m high needs an elevating work platform to inspect the upper levels (WorkSafe Victoria).
- Cost: see what a formal inspection costs.
The checklist
| Area | What to look for | What the guidance says to do |
|---|---|---|
| Beams | Heavy deflection; beam connectors bent into a "V" where two beams meet an upright; permanent set in unloaded beams | Signs of overloading. Have a competent person or engineer inspect. |
| Beams and welds | Obvious hits from pallets or forklifts; cracked welds | Replace damaged beams. Have welds checked by a competent person after minor damage. |
| Safety clips and connectors | Missing clips; fixed bolts used to hold beams | Replace missing clips with the manufacturer's design. Fixed bolts must not be used. If clips keep being dislodged, ask the manufacturer or installer why. |
| Popped beams | A beam hanging on one end connector | Could collapse. Treat as urgent. |
| Uprights and footplates | Damage, twist, splits or cracks | Replace the upright or splice in a new section, and replace damaged footplates. Splices should be manufacturer-approved. |
| Splices | Position and condition | Above the first beam level and not below 1.5 m; no more than one splice between adjacent beam levels. |
| Plumb | Racking out of vertical | Usually from incorrect installation, impact, overloading or floor settling. Contact the manufacturer or installer. |
| Braces | Bent horizontal or diagonal braces | Replace. Deviation from a 1 m straight edge should not exceed 10 mm in either plane. |
| Floor fixings | Missing or damaged anchors; loose anchor bolts | Replace damaged fixings and the footplate. At least two anchors per footplate. Check anchor bolts are tight. |
| Load signs | Missing or illegible safe working load signs; configuration changed since signs were made | Signs should show manufacturer, supplier, installation date, designer, unit load limit and limits per beam level and per bay. Any change to configuration alters safe loads. |
| Loads and pallets | Overloaded beams or bays; pallets overhanging, unstable, not keyed into beams; wrong pallet type or size; unit loads touching uprights | Stay within safe working loads. Check pallets suit the racking and goods are secured. |
| Protection | Missing upright or end-of-rack protectors; no rear protection on single-row racking with pedestrian access behind | Regulators recommend protectors and rear protection in those cases. |
Damage: report, tag and classify
WorkSafe Victoria describes classifying damage under section 5.5 of AS 4084.2:2023 (WorkSafe Victoria):
- Very serious damage: needs immediate attention. Off-load all affected bays and repair before reuse.
- Hazardous damage: needs action as soon as possible. Tag it with a dated tag, do not reload the affected locations after goods are removed, and repair. If it is not repaired within 4 weeks, reclassify it as very serious.
- Acceptable damage: needs surveillance. Tag it, record the date and review at the next inspection within 12 months; if it has worsened, treat it as hazardous.
SafeWork NSW and SafeWork SA also say damage should be reported to a supervisor immediately and recorded, for example with coloured stick-on tags (SafeWork NSW, SafeWork SA).
Do not do these
- No welding on cleats or bearers, and no physical alterations to uprights, braces, beams or components without a competent person's approval (WorkSafe Victoria, SafeWork NSW).
- Use replacement parts from the equipment manufacturer. If alternative parts must be used, SafeWork SA says an engineering report should confirm compatibility (SafeWork SA).
- Do not climb on racking (WorkSafe Victoria).
Using this when buying used racking
The same questions are a sensible way to inspect used stock before you buy: see Used racking for sale and Gumtree and marketplace checks. For what the standard is and covers, read AS 4084 explained. City price notes: Brisbane pallet racking cost, Sydney pallet racking cost, Melbourne pallet racking cost, Perth pallet racking cost, Adelaide pallet racking cost.
WorkSafe Victoria's guidance was reviewed on 8 April 2024, and SafeWork NSW and SafeWork SA publish their own versions. Check the current page for your state regulator. In an emergency or serious incident, follow your regulator's notification rules.
Estimate your rangeHow to compare quotes
Related guides
- Inspection costTypical annual inspection prices and what you get.
- AS 4084 explainedWhat the standard covers and what to ask.
- Used racking for saleListing prices, savings claims and a buying checklist.
- Compare quotesA checklist to line quotes up like for like.
Prices vary, get quotes. Every range on this page comes from public pages we read in Nov 2026 and links to its source. They are indicative, not quotes, and not advice. See regulator checklists we cited.