Compliance & Safety
Why Regular Racking Audits Are Essential
Australian Standard AS 4084:2023 requires warehouse operators to conduct formal racking inspections at least every 12 months. Damaged or non-compliant racking systems pose serious risks including structural collapse, product loss, and workplace injuries. Regular audits help you:
- Meet your obligations under AS 4084:2023 and workplace health and safety legislation
- Identify damage before it escalates into a critical safety hazard
- Reduce insurance liability and demonstrate due diligence
- Extend the operational lifespan of your racking infrastructure
- Avoid unplanned downtime and expensive emergency racking repairs
Australian Standards
AS 4084:2023 Compliance Requirements
The updated Australian Standard AS 4084:2023 sets out clear guidelines for the design, installation, and ongoing maintenance of steel storage racking. Our audits are conducted in full compliance with this standard, ensuring your warehouse meets every requirement.
What We Inspect
Comprehensive Component-Level Assessment
Reporting
Colour-Coded Reporting System
After each audit, you receive a detailed report using an industry-standard colour-coded risk classification:
Red — Critical Risk
Immediate unloading and isolation required. The affected bay must be taken out of service until repairs are completed.
Amber — Medium Risk
Damage has been identified that requires repair within 28 days to prevent escalation.
Green — Low Risk
Minor cosmetic damage or wear. Monitor at next scheduled inspection.
Inspection Cadence
Annual Audit vs Quarterly Inspection vs Daily Walk-Around
AS 4084:2023 expects a layered inspection regime. Each cadence has a different purpose, performer and depth of assessment.
| Aspect | Annual Expert Audit | Quarterly Inspection | Daily Walk-Around |
|---|---|---|---|
| Frequency | Every 12 months | Every 3 months | Each shift / daily |
| Performed by | Qualified external inspector | Trained warehouse supervisor | Forklift operators & floor staff |
| Depth | Full component-level assessment of every bay | Visual sweep with measurement of obvious damage | Spot-check for new impacts and obstructions |
| Output | Formal AS 4084 report with RAG ratings & photos | Written log with action list | Verbal report or hazard tag |
| Documentation | Required for compliance & insurance | Recommended internal record | Encouraged — feeds the next inspection |
| Best for | Demonstrating PCBU due diligence | Catching escalation between expert audits | Catching forklift impacts within hours, not weeks |
Our Process
Our Racking Audit Process
We keep disruption to your operations to a minimum. Here's what to expect:
Initial consultation
We discuss your warehouse layout, racking brands (Dexion, Colby, Macrack, BHD and more), and any known concerns.
On-site inspection
Our technicians systematically inspect every frame, beam, and connection point while your warehouse continues to operate.
Detailed report
You receive a comprehensive colour-coded report with photographs, risk ratings, and recommended corrective actions.
Repair quotation
If damage is found, we provide a transparent quote for all necessary pallet racking repairs.
Follow-up
We schedule your next 12-month audit to keep you continuously compliant.
Brands
Racking Brands We Audit
Our team has hands-on experience with all major racking systems used across Australian warehouses. No matter the brand, age, or configuration, we have the expertise to assess your system accurately.
Service Areas
Where We Provide Racking Audits
We deliver professional racking audits services across Queensland and New South Wales — from major metropolitan centres to regional locations.
Queensland
Our racking audits team covers south-east Queensland and beyond — servicing warehouses, distribution centres, and industrial facilities from Brisbane to Cairns.
New South Wales
We provide racking audits across Greater Sydney, the Hunter Valley, Illawarra, and regional NSW — including interstate projects between QLD and NSW.
FAQ
Frequently Asked Questions
Free Resource
AS 4084:2023 Racking Audit Checklist
Use this checklist as a guide for routine in-house visual inspections between formal expert audits. It covers the key areas assessed during a professional racking safety inspection.
Uprights & Frames
- Check for bends, dents, or deformation greater than 3 mm
- Inspect for rust, corrosion, or paint damage
- Verify plumb alignment within tolerance
- Confirm bracing connections are secure
Beams & Connectors
- Inspect beam faces for impact damage or deflection
- Check beam-to-upright locking pins are engaged
- Verify beam load capacity labels are present and legible
- Confirm connector integrity — no cracks or deformation
Bracing & Cross Members
- Check horizontal and diagonal bracing for damage
- Verify all bolted connections are tight
- Inspect for missing or bent bracing members
Floor Fixings & Base Plates
- Confirm all base plates are anchored to the floor
- Check anchor bolts for tightness and corrosion
- Inspect concrete around fixings for cracking or spalling
- Verify base plate condition — no bending or distortion
Signage & Load Notices
- Confirm Safe Working Load (SWL) signs are displayed on every row
- Verify load notices match current racking configuration
- Check for visible safety and aisle marking signage
Protection & Accessories
- Inspect column guards and end-of-aisle protectors for damage
- Check mesh or timber decking for integrity
- Verify fork-lift guide rails are in place where required
- Confirm pallet backstops are installed and undamaged
Related Guides
Go Deeper on Racking Audits & Compliance
Free, in-depth resources covering the Standard, inspection cadence, RAG damage classification and how to choose an inspection provider.
Client Testimonials
What Our Clients Say
Warehouse operators across Queensland and New South Wales trust us to keep their racking safe, compliant, and performing at its best.
"Matt and his team completed a full racking audit of our 8,000 sqm warehouse in under two days. The colour-coded report made it easy for management to prioritise repairs. Highly recommended."
James T.
National Distribution Centre — Brisbane, QLD
"We needed galvanised racking installed in our freezer facility. The team handled everything from design to install — on time and fully compliant with AS 4084. Professional from start to finish."
Sarah M.
Cold Chain Logistics — Sydney, NSW
"After a forklift collision damaged several uprights, Pallet Racking Maintenance were on-site within 24 hours. Repairs were completed safely with zero disruption to our operations."
David K.
Regional Warehouse Solutions — Gold Coast, QLD
"We've used their maintenance program for over two years. The scheduled inspections catch small issues before they become expensive problems. Great value and peace of mind."
Karen L.
E-Commerce Fulfilment Hub — Newcastle, NSW
Book Your Racking Audit Today
Call Matt Gade on 0407 009 493 or contact us online for a free, no-obligation consultation.