Racking and storage inspection checklist

Racking & Storage Systems

Workplaces are required to undertake self inspection of warehouse racking and storage areas for damage, overloading, unstable loads, falling-object risks and unsafe storage practices. The inspection focuses on whether the racking and storage arrangements are being used and maintained safely. This is additional to the AS/NZS 4084:2023 requirement for a formal racking inspection at a minimum every 12 months. Self inspection alone is not sufficient. Since the 2023 update, the annual inspection must be carried out by an external, independent provider.

1. General Racking Condition

• Racking condition: Uprights, beams, braces, frames and connections are free from significant damage, distortion, cracking or corrosion.
• Impact damage: No significant damage from forklifts, pallet jacks or other mobile equipment.
• Stability: Racking appears stable, plumb and properly supported.
• Connections: Beam-to-upright connections, locking pins and other retaining devices are correctly fitted and secure.
• Base plates: Base plates are present, secure and properly supported.
• Floor fixing: Racking is securely anchored where required.
• Bracing: Horizontal and diagonal bracing is present and undamaged.
• Repairs: Damaged components have not been straightened, welded, modified or repaired without appropriate approval.
• Corrosion: There is no corrosion likely to affect the structural integrity of the racking.

2. Pallets & Loads

• Pallet condition: Pallets are in good condition and suitable for the loads being stored.
• Load stability: Pallets and stored materials are stable and unlikely to fall or collapse.
• Load distribution: Loads are evenly distributed and positioned correctly on beams.
• Overloading: Racking is not visibly overloaded.
• Load limits: Safe working load information is clearly displayed and understood.
• Load height: Loads are stored within the designated height and configuration limits.
• Pallet position: Pallets are positioned correctly with adequate support and do not project dangerously into aisles.
• Loose items: Small or loose items are secured to prevent them falling from elevated levels.

3. Protection Against Impact

• Rack protection: Suitable upright guards or other protection are installed where forklifts or other vehicles could strike the racking.
• Protection condition: Rack guards are secure and have not been significantly damaged.
• Aisle clearance: Adequate clearance is maintained for forklifts, pallet jacks and pedestrians.
• Traffic management: Vehicle routes and racking arrangements minimise the risk of vehicle impact.
• Forklift operation: Forklift operators have sufficient room to safely place and retrieve loads.

4. Falling Objects

• Back protection: Suitable mesh, panels or other protection is provided where stored goods could fall into work areas or traffic routes.
• End protection: Exposed ends of racking are protected where there is a risk of falling goods or vehicle impact.
• Stacking: Materials are not stacked in a way that could cause them to topple.
• Overhanging loads: Loads do not unnecessarily overhang the racking or obstruct walkways.
• Elevated storage: Items stored at height are appropriate for the racking system and securely positioned.

5. Inspection & Maintenance

• Routine inspections: Racking is included in the warehouse’s routine inspection programme.
• Damage reporting: Workers know how to report damaged racking or unsafe storage.
• Damage identification: Damaged components are clearly identified and isolated from use where necessary.
• Repairs: Reported damage is assessed and repaired or replaced promptly.
• Inspection records: Records of racking inspections and significant repairs are available.
• Changes: Changes to the racking layout or configuration have been appropriately assessed.
• Unauthorised alterations: No unauthorised modifications or additions have been made to the racking.

6. Housekeeping Around Racking

• Aisles: Aisles between racking are clear of pallets, packaging, rubbish and other obstructions.
• Emergency access: Emergency exits, fire equipment and evacuation routes are not obstructed by stored goods.
• Spills: Spills around racking are cleaned promptly.
• Waste: Damaged pallets, packaging and waste are removed from storage areas.
• Lighting: Lighting is adequate to safely inspect, load and access racking.
• Access: Workers are not climbing on racking or pallets to access stored goods.

7. Safe Storage Practices

• Heavy items: Heavy items are stored at lower levels where practicable.
• High-risk materials: Hazardous, unstable or bulky materials are stored in designated areas.
• Incompatible materials: Materials that could create a hazard if stored together are appropriately separated.
• Access equipment: Suitable equipment is provided for retrieving goods from elevated levels.
• Manual handling: Storage arrangements minimise excessive lifting, reaching, twisting or awkward postures.
• Pedestrian safety: Pedestrian access around racking is separated from vehicle movements where reasonably practicable.

8. Documentation & Controls

• Racking layout: Current racking layout is available where required.
• Capacity information: Maximum permissible loads are identified for relevant racking.
• Manufacturer information: Manufacturer or supplier information is available where necessary.
• Competency: Workers operating forklifts or other equipment around racking are appropriately trained and authorised.
• Emergency procedure: There is a process for dealing with damaged or unstable racking.
• Incident follow-up: Racking damage resulting from vehicle impact or other incidents is investigated and corrective action taken.