Pallet Racking Safety Audits & AS4084 Compliance

Ensure your warehouse operations remain safe, compliant, and WorkSafe-ready.

Direct Storage Systems provides certified on-site pallet racking inspections and safety audits across Geelong, the Surf Coast, and Western Melbourne. We identify structural damage, overloaded beam levels, and installation hazards before they become costly safety incidents, delivering straightforward compliance reports and actionable repair solutions.

Why Regular Racking Audits Are Essential

Under Australian Standard AS 4084:2023 (Steel Storage Racking) and regional WorkSafe guidelines, pallet racking systems must be formally inspected at least once every 12 months by a competent person. Active warehouses, busy logistics yards, and commercial stockrooms experience daily forklift impacts, structural shifting, and evolving load demands that can compromise rack integrity without obvious visible signs.

Failing to maintain compliant racking risks catastrophic collapses, severe workplace injuries, substantial WorkSafe fines, and invalidated commercial insurance policies.

What Our Racking Audit Covers

Our thorough on-site inspection evaluates every component of your storage system against current Australian manufacturing and safety benchmarks:

• Upright & Frame Integrity: Measuring column deflection, bends, cracks, and twisting caused by forklift collisions or base floor settling.
• Beam Deflection & Load Limits: Checking beam spans for permanent sag, verifying safety locking pin engagement, and ensuring beam levels match rated safe working capacities.
• Floor Anchors & Baseplates: Inspecting slab fixings, footplates, and shims to ensure frames remain securely anchored without loose or sheared bolts.
• Safety Accessories & Protection: Evaluating the condition of corner post protectors, rack-end barriers, anti-collapse mesh, and pallet back-stops.
• Safe Working Load (SWL) Signage: Verifying that clear, certified load notices are displayed prominently on every rack bay with accurate manufacturer data.
• Aisle Clearance & Operational Hazards: Assessing pallet overhang, aisle widths, and flue space compliance for fire safety regulations.

The Audit Process

• On-Site Assessment: A qualified inspector visits your facility to conduct a bay-by-bay physical inspection of all selective, drive-in, double-deep, or cantilever racking systems.
• Traffic-Light Risk Categorisation: Issues are categorised using standard risk classifications (Green for operational, Amber for damage requiring scheduled maintenance, and Red for critical hazards requiring immediate offloading).
• Comprehensive Audit Report: You receive a certified digital report detailing specific damaged locations, photos, CAD-mapped bay references, and clear remediation steps.
• Fast Local Repair Support: Direct Storage Systems carries compatible replacement beams, uprights, frame splices, and safety locks at our North Geelong warehouse to resolve rectification work quickly.

Book Your On-Site Safety Inspection

Protect your team, secure your inventory, and keep your site 100% compliant. Contact our North Geelong team today to schedule an on-site measure and racking safety audit for your facility.