Let’s be honest: warehouses are high-energy environments. Between tight turnaround times and forklifts maneuvering heavy loads, your racking system takes a beating. While efficiency is the goal, safety is the foundation that keeps everything running.
At Rack Safe Industries, we view racking safety not just as a compliance box to tick, but as a critical component of your team’s well-being. Today, we are focusing on the "legs" of your operation: Racking Uprights.
Based on the Australian Standard AS4084:2023, here is what you need to know to identify damage, assess risks, and keep your facility secure.
Think of uprights as the skeleton of your storage system. These are the vertical columns that bear the compressive weight of every pallet you store. They are designed to be strong, but they aren't invincible.
Because they are often the first point of contact for a reversing forklift or a misplaced pallet, their structural integrity is paramount. Even a small dent can compromise the capacity of an entire frame, putting your inventory and, more importantly, your staff at risk.
You don't need to be a structural engineer to spot the warning signs, but you do need to know where to look. According to AS4084:2023, these are the most common "scars" your uprights might sustain:
.png)
.png)
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.
If you find damage, please resist the urge to fix it yourself. Racking is a highly engineered system, and "DIY" repairs often violate standards and void warranties.
Need help assessing your current racking status? At Rack Safe Industries, we are ready to help you navigate AS4084:2023 with practical, honest advice.
Regular racking inspections are not just a box-ticking exercise—they’re vital for preventing accidents and costly downtime. Inspections identify early signs of wear, damage, or improper use. By catching these issues early, you can address them before they become hazards, ensuring your warehouse remains a safe environment for everyone.
Inspections also help you stay compliant with legal obligations. If you’re unsure about the process, consider scheduling a professional audit. Experts can provide tailored advice, highlight potential risks, and recommend practical solutions to keep your operations running smoothly.
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.
