How to Prepare for a Racking Audit: AS 4084:2023 Guide

A professional racking audit is the most effective way to ensure your warehouse storage systems are safe, compliant, and fit for purpose. Whether it's your first audit or an annual review, proper preparation helps your auditor work efficiently and ensures nothing is overlooked.

Why Racking Audits Matter

Damaged, overloaded, or non-compliant racking poses a serious risk to warehouse workers and stock. Australian Standard AS 4084:2023 recommends formal expert inspections at least every 12 months. Both Workplace Health and Safety Queensland and SafeWork NSW expect employers to maintain safe storage systems. Regular audits help you:

• Identify structural damage before it leads to a collapse
• Meet your WHS obligations as an employer
• Maintain accurate load capacity records
• Plan maintenance and repair budgets effectively
• Demonstrate due diligence to insurers and regulators

What Does an Auditor Inspect?

A qualified racking auditor will systematically check every component of your storage system. For more on general safety requirements, see our guide to pallet racking safety requirements in Australia. Key areas include:

Uprights and Frames

Every upright column is checked for bends, dents, corrosion, and alignment. Deformation exceeding tolerances set by AS 4084:2023 will be flagged for repair or replacement.

Beams and Connectors

Beams are inspected for deflection, impact damage, and correct locking pin engagement. Connectors are checked for cracks, bending, and secure attachment.

Floor Fixings

Base plates and anchor bolts are examined for tightness, corrosion, and concrete integrity around each fixing point. Proper anchoring is critical for racking that has been recently installed or relocated.

Load Signage

Every row must display a legible Safe Working Load (SWL) notice. The auditor will verify that signage matches the current racking configuration.

Protection Equipment

Column guards, end-of-aisle protectors, pallet backstops, and mesh decking are assessed for damage and correct placement.

How to Prepare Your Warehouse

• Clear access — ensure aisles are clear so the auditor can walk the full length of every row
• Gather documentation — have previous audit reports, racking layout drawings, and load capacity data available
• Notify staff — inform warehouse personnel about the audit date and any access requirements
• Check signage — confirm SWL signs are in place (even if outdated, their presence speeds up the audit)
• Note known damage — compile a list of any damage your team has already identified
• Ensure adequate lighting — the auditor needs to see all components clearly, including upper beam levels

For guidance on workplace safety preparation, visit Safe Work Australia.

Understanding the Audit Report

After the inspection, you'll receive a detailed report. Most professional reports use a colour-coded risk rating system:

• Green — no action required; component is in good condition
• Amber — minor damage; repair should be scheduled within a reasonable timeframe
• Red — critical damage; the bay must be immediately unloaded, isolated, and repaired before returning to service

The report serves as both a compliance record and a practical repair priority list for your maintenance team.

Book Your Racking Audit

Pallet Racking Maintenance provides AS 4084:2023 compliant racking audits across Queensland and New South Wales. Our QBCC licensed inspectors have audited thousands of bays in warehouses of all sizes — from small storage facilities to large-scale distribution centres.