The three options
Repair, reinforce or replace
| Option | Best for | Typical cost (AU) | Lead time |
|---|---|---|---|
| Manufacturer repair kit | Single Amber upright, OEM kit available | $300–$600 supplied | 1–2 weeks |
| Engineered reinforcement | Repeat-impact zone, retain bay use | $800–$1,800 per frame | 2–4 weeks |
| Full upright replacement | Red rating, no OEM kit, multiple frames | $800–$1,700 per upright installed | 2–6 weeks |
Decision logic
How to choose between the three
- If the OEM publishes a repair kit AND damage is single-Amber → repair kit.
- If the column has been hit twice in 12 months → reinforce.
- If multiple Amber findings on one frame → replace the whole upright.
- If the rating is Red and progressing → replace.
- If the brand is end-of-line and no kit exists → reinforce or replace.
- If the bay sits in a high-throughput aisle → reinforce regardless.
Always check the OEM first
Dexion, Colby, Macrack, BHD, Unirack and Spacerack all publish repair-kit catalogues. Sourcing the original manufacturer's part keeps the warranty intact and is the simplest path through an AS 4084 audit.
Downtime planning
Plan the unload window
Replacement and reinforcement both require the affected bay — and usually the bay above and below — to be unloaded for several hours. Schedule the work at shift change or during a planned slow period to minimise operational impact.
Documentation
What goes in the repair record
- Photos of the damage before repair, with measurement reference.
- Photos of the installed repair / replacement.
- Manufacturer part numbers and certification.
- Engineer's sign-off (for reinforcement or non-standard repairs).
- Installer's QBCC licence reference.
- Date and time of work, with the bay's load notice updated.