The triggers
The five stop-work triggers under AS 4084:2023
| Trigger | Threshold | Why it's Red |
|---|---|---|
| Upright lean | >5 mm/m | Frame buckling risk multiplies |
| Beam deflection | >L/180 or permanent set | Yield exceeded — beam compromised |
| Baseplate gap | >3 mm OR anchor failure | Whole frame can lift or rotate |
| Bracing | Missing or >5 mm bend | Columns left to act alone |
| Cumulative Amber | ≥2 in one frame | Combined risk equals Red |
The 60-minute rule
What to do when you find critical damage
The first hour after a Red finding is the most legally important. Document the response and you are protected. Skip the documentation and the entire safety system unravels.
- Step 1 — barricade the aisle and stop forklift traffic.
- Step 2 — unload the affected bay onto the floor or a neighbouring bay (at reduced height).
- Step 3 — photograph the damage with a tape or ruler in the frame.
- Step 4 — log the finding in the incident register with date, time and inspector name.
- Step 5 — notify the PCBU (site manager / officer) in writing.
- Step 6 — book the repair and keep the bay empty until sign-off.
Documentation is the defence
Most failed insurance claims after a racking incident in Australia trace back to a missing or incomplete post-incident log. The 60-minute checklist exists to give you evidence you acted reasonably.
PCBU duty
Your legal duty when damage is critical
Under the WHS Act, the PCBU must take action to control any risk that could cause serious injury, so far as is reasonably practicable. Leaving a Red-rated bay loaded is, on its face, a failure of that duty. Officers can be prosecuted personally under section 27 of the Act.
Common myths
Myths that get warehouses in trouble
- 'It's been like that for months' — irrelevant; the duty is current, not historic.
- 'We reduced the load' — load reduction does not reset a Red rating.
- 'It's only the bottom shelf' — the upright is shared by every bay above.
- 'We'll fix it next shutdown' — Red findings cannot wait for a planned shutdown.
- 'The forklift driver said it's fine' — only a competent person re-rates damage.