Hey there, warehouse and operations managers!
If you’re knee-deep in pallets, forklifts, and tight deadlines, you already know your racking system is the backbone of the whole operation.
But the real heroes? The frames that hold everything steady day after day.
In our new series on racking components (following our popular post on the AS4084:2023 changes), we’re starting right at the base –literally.
Today we cover exactly what pallet racking frames do, the damage they commonly suffer, and the clear repair rules set out in AS4084.2:2023 (the Operation & Maintenance part that applies right across New Zealand).
Let’s keep it simple, practical, and safety-first.
Pallet racking frames (also called uprights or frames) are the vertical steel assemblies that form the sides of every bay in selective pallet racking.
Each frame is made up of:
Their job is straight forward but critical: they carry the compressive load from the beams and pallets above, transfer that weight safely to the ground, and provide lateral stability against forklift knocks and seismic movement.
Without sound frames, the whole system loses its rated capacity – fast. That’s why AS4084.1:2023 (Design) and AS4084.2:2023 (Operation & maintenance) work together to keep them strong and compliant.
You don't need to be a structural engineer to spot the warning signs, but you do need to know where to look.
Frames take the hardest hits in any busy operation. The most frequent problems we spot during Rack-Safe inspections are:
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Damage isn't merely cosmetic. Even a seemingly minor dent on a heavily loaded rack can act as a structural time bomb, potentially leading to failure if ignored.
One of the most helpful aspects of AS4084:2023 (specifically Clause 5.5) is that it simplifies risk assessment into a color-coded system. This helps you prioritize exactly what needs to be done and when.
Status: Acceptable / Minor damage.
Action: The racking is safe to use, but the damage has been noted. You don't need to unload the rack, but you must monitor it closely during future inspections to ensure it doesn't get worse.
Status: Damage requiring action soon.
Action: You have a window of opportunity. The affected section is damaged beyond safe limits but doesn't require immediate isolation.
Status: Severe damage / Critical condition.
Action: This is an emergency stop.
Compliance isn't just about the annual audit; it's about what happens on a Tuesday afternoon when a driver accidentally bumps a frame.
1. Empower your team: Drivers often hide minor accidents for fear of reprimand. Shift the culture: encourage immediate reporting of "oops" moments. It is better to inspect a dent now than deal with a collapse later.
2. The Inspection Cycle:
3. Keep the paperwork: Under the standard, you need a paper trail. Maintain a logbook of all damage reports, photos, severity ratings (Green/Amber/Red), and the repairs performed. This is your proof of due diligence.
PRO TIP straight from the standard: Fit upright protectors (minimum 400 mm high) on all aisle and end frames. They dramatically cut impact damage before it even starts.
guided by the standard and assessed by a competent person.
One compromised frame can turn a minor forklift clip into a major collapse risk. Staying on top of frame condition keeps your team safe, avoids downtime, reduces insurance headaches and keeps you fully compliant with WorkSafe expectations.
Don’t wait for the next incident. At Rack-Safe, our team specialises in AS4084.2:2023 racking inspections, damage classification, repair and full frame replacement advice.
We’ll give you a clear, colour-coded report, and make sure your records are audit-ready.
Contact the Rack-Safe team today – whether you need a one-off check or ongoing compliance support.
We’re here to keep your warehouse standing strong.
Safe racking, everyone!
Have a question or need a quote? Reach out and our Auckland team will help you with racking inspections, 'as built' drawings, or advice on standards.
