The four layers
The four layers of racking safety
| Layer | What it controls | Owner |
|---|---|---|
| Design | System selection, load capacity, layout | Engineer / installer |
| Training | Operator competence, supervisor skill | PCBU |
| Protection | Column guards, barriers, signage | PCBU + facilities |
| Inspection | Daily, weekly, monthly, annual checks | PCBU + external auditor |
PCBU duties
What the PCBU has to do
The Person Conducting a Business or Undertaking carries the legal duty for workplace safety under the WHS Act, as adopted in Queensland and New South Wales. For racked warehouses, the duty translates into specific operational obligations:
- Provide racking that meets AS 4084:2023.
- Provide load notice signage at every aisle entry.
- Train operators (HRWL LF or equivalent).
- Maintain inspection records (daily, weekly, monthly, annual).
- Respond to damage within documented timeframes.
- Notify the regulator within 24 hours of a dangerous incident.
- Keep records for at least 5 years.
Officer liability
Training
Training that actually moves the needle
The single biggest predictor of low racking damage is forklift operator competence. Beyond the HRWL licence, successful warehouses run regular refresher training, written aisle protocols and toolbox talks tied to recent damage findings.
Notifiable incidents
When you must notify the regulator
WHS regulations require notification within 24 hours when an incident causes — or could have caused — death, serious injury or a "dangerous incident". Racking collapse, partial collapse and any uncontrolled load fall are all notifiable, regardless of injury outcome.
- QLD: notify Workplace Health and Safety Queensland on 1300 369 915.
- NSW: notify SafeWork NSW on 13 10 50.
- Preserve the scene until the regulator releases it.
- Photograph the incident from multiple angles.
- Capture witness statements while memory is fresh.
- File the written notification within 48 hours.