Pallet racking is a fabulous way of getting more from your warehouse space. It lets you store more items across the warehouse while simplifying and improving safety. With that being said, companies must be aware of the pallet racking inspection requirements. Regular checks are essential for maintaining workplace health & safety, so we’ve developed this ultimate guide to pallet racking inspections. 


At PRQ, we’ve been providing pallet racking inspections across Australia for many years. Our expertise in this field means we know what it takes for your business to remain compliant. We’ll provide a full-scale audit of your warehouse to check that all pallet racking equipment is secure and safe. This guide is designed to give you a comprehensive overview of what happens during pallet racking inspections and the key things to be aware of. 

What Types Of Pallet Racking Inspections Are Required? 

It is a legal requirement under the Australian Standard (AS4084-2023) that all businesses utilising steel storage racking (otherwise known as pallet racking) must undergo regular pallet racking inspections. 


These inspections are split into three main categories: 


  • Pre-Start Inspections – This refers to a pallet racking inspection that’s conducted before the system is installed. It must be conducted by a qualified racking system expert (such as the team at PRQ) and the purpose is to ensure the whole system is compliant with the Australian Standard. An inspection at this stage will prevent warehouses from installing potentially dangerous pallet racks that could cause injuries or safety risks. 

  • Ongoing Inspections – The Australian Standard states that a pallet rack inspection should be carried out at least once every 12 months. Businesses must assess their pallet rack usage to determine if more frequent inspections are necessary. Generally speaking, if pallet racks are used to store heavy items and are constantly under lots of stress, then it is better to conduct ongoing inspections more frequently. 

  • Damage Inspections – If your pallet racks become damaged, it is critical to have them inspected. This determines if the system remains structurally stable and continues to meet all the essential safety criteria. If not, then new racks will be required (and they will then need a pre-start inspection). 

What Is Checked During A Pallet Racking Inspection?

Throughout a pallet racking inspection, our team will check for countless things that may pose safety risks. Some of the key criteria include: 


  • Checking the frame condition for signs of corrosion or rust
  • Identifying any signs of overloaded beams
  • Assessing the condition of anchor bolts
  • Ensuring there’s no structural damage
  • Make sure the pallet racking is installed correctly and by licensed professionals


Some additional requirements came in with these new Australian Standard regulations in 2023. In our experience, this is where many warehouses fail a pallet racking inspection. Even if your pallet racking passed previous inspections before 2023, it could fail the new ones if the following aren’t present: 


  • All End Frames close to trafficable areas must be extended by at least 50% of the height of the unit load to be stored on the top pallet beam level
  • There must be at least 400mm high corner post protectors on each individual run of racking


Don’t worry if your racking doesn’t comply with these regulations – that’s the purpose of a pallet racking inspection. PRQ will carry out the audit and present a series of things that can be done to bring your pallets into compliance. Sometimes it’s as simple as ensuring you have the correct pallet racking protection in place. 

Why Are Regular Pallet Racking Inspections So Important?

A yearly pallet racking inspection is essential to comply with Australian Standard AS4084-2023. Failure to do so can result in financial penalties and may restrict your company’s ability to operate until you comply. 


However, why were these standards introduced in the first place? Regular pallet racking inspections are beneficial for everyone as they help with the following: 


  • Improving Warehouse Safety – The risk of injuries related to pallet racking will decrease with regular inspections. You stay on top of things and avoid instances when a rack might cause an accident due to regular wear and tear. 

  • Save Money By Making Your Racks Last Longer – Pallet racking inspections will help you elongate the lifespan of your pallet racking system. You’ll keep the whole system in the best condition possible, which limits the need for constant repairs while stopping you from needing to replace racks too often. As a result, your business will save a fortune over time. 

  • Maintain A Positive Brand Image – You don’t want to be caught out as a non-compliant business. It can ruin your brand image and make it difficult to draw in customers. Obtaining regular inspections helps you uphold a positive image as a brand that cares for health & safety.