The four modes
The four damage modes every inspector tracks
- Upright damage — front-to-back lean, side bow, twist or fork-tip dent at floor level.
- Beam damage — permanent deflection, dislodged end-connectors, missing safety pins.
- Baseplate damage — anchor failure, slab spalling, lifted or rotated plates.
- Bracing damage — bent, missing or fractured horizontal and diagonal members.
Tolerances
The AS 4084:2023 mm tolerances
| Component | Green | Amber | Red |
|---|---|---|---|
| Upright lean (front-to-back) | ≤3 mm/m | 3–5 mm/m | >5 mm/m |
| Upright side bow | ≤3 mm over 1m | 3–5 mm over 1m | >5 mm over 1m |
| Beam deflection (loaded) | ≤L/200 | L/200 – L/180 | >L/180 |
| Baseplate gap | 0 mm | 1–3 mm | >3 mm |
| Bracing | Straight | Bent ≤5 mm | Missing or >5 mm |
Cumulative damage
Two Amber findings in the same upright frame should be treated as Red. The Standard expects engineering judgment on cumulative damage, not just single-component readings.
Causes
Why racking gets damaged in Australian warehouses
Forklift impact accounts for the overwhelming majority of damage seen during AS 4084 audits in QLD and NSW. The rest splits between overloading, incorrect installation and environmental factors such as condensation in cold rooms or vibration near heavy industrial plant.
- Forklift impact at fork-tip height (the #1 cause).
- Pallet overhang catching the upright on retrieval.
- Overloading — exceeding the published beam UDL.
- Out-of-tolerance install (poor plumb, wrong shims).
- Slab issues causing baseplate movement.
- Cold-room corrosion under condensation drips.
The decision
Repair, reinforce or replace
| Option | When it fits | Typical lead time |
|---|---|---|
| Repair (manufacturer kit) | Single Amber upright, OEM kit available | 1–2 weeks |
| Reinforce (engineered) | Recurring impact zone, retain bay use | 2–4 weeks |
| Replace (full upright) | Red rating, multiple Amber findings, no OEM kit | 2–6 weeks (parts) |