Racking Safety Audits

Warehouse racking is a central component of many warehouse storage systems, and constant use can result in damage and general wear and tear. This is why racking safety audits must be completed every 12 months to ensure your warehouse storage system complies with Australian Standards AS 4084:2023.

How Safety Audits Work

Safety audits are conducted to check that your warehouse storage systems are safe and not going to pose any risks. To comply with Australian regulations, these checks need to be completed every 12 months, but it’s wise to audit the safety of your warehouse racking on a more frequent informal basis: at least once every few months. The types of racking requiring these checks are:

• Pallet racking
• Vertical racking
• Cantilever racking
• Galvanised racking

When it comes to both the formal and informal inspection of your racking section, 5.2 (Inspections) of AS 0484:2023 states that:

5.2.1 General

Inspections of racking and unit loads shall be conducted to check that racking is being used as specified and damage is being reported and rectified.

Inspections, reports and repairs relating to racking shall be documented and retained by the end user until the racking is removed from service

Damage incurred, however minor, shall be reported and documented immediately to enable the effect on safety to be immediately assessed.

Hazardous situations involving the operation or maintenance of the racking installation shall be reported, actioned and documented immediately.

5.2.3 Formal inspections

Formal inspections shall be conducted by a competent person.

Formal inspections shall be conducted at intervals not exceeding 12 months

The actual frequency of such inspections, if less than 12 months, should be based on

1. The results of a risk assessment: or
2. The recommendation of a competent person for formal inspections

A Safety Audit by All Storage Systems

Classified as a competent external party All Storage Systems are qualified to conduct your pallet racking audit to ensure your current system meets required safety standards. When you contact us for a safety audit, you will receive:

• A visual site examination and assessment by qualified personnel
• A compliance report that details risks and recommendations
• A color-coded report showing the level of action required

When a formal inspection is conducted by All Storage Systems, we will assess your racking following the checklist as stated in AS 0484:23023 to ensure your racking complies with the standard. The following checklist should also be used for any informal inspections that you conduct.

5.2.4 Inspection check list

Inspection, both formal and informal, shall –

1. Determine if storage equipment is being applied and used as specified
2. Determine if working load limits for unit and bay loads are current and being adhered to
3. Determine if unit loads adhere to specified dimensions such that operating clearances are maintained as specified
4. Determine if unit loads are stable
5. Determine if the racking installation has been modified using the information specified on the load sign or configuration drawings held on sight
6. Check that all signage is current, legible and free from damage and obstruction
7. Determine if all racking components including frames, beams, floor fixings, bracing and ancillary devices are consistent with the design
8. Assess for damage to racking components to racking uprights, beams, baseplates and frame bracing caused by impact
9. Check for out-of-plumb (non-vertical) racking uprights in both the cross-aisle and down-aisle directions
10. Check for absence of pallet beam safety locks and for disengagement of beam connectors from racking uprights
11. Examine beam connectors for deformation or signs of weld cracking
12. Identify any corrosion of racking components
13. Inspect base plates and floor fixings
14. Examine the floor condition, checking for signs of deformation, out of level and cracks
15. Check that racking is
    1. Not attached to a building or
    2. If attached to a building has approval for such attached from a structural engineer

As part of our audits you will receive a compliance report that details any risks and recommendations along with a colour coded report showing the level of action required. The colour coded report follows the levels of damage as stated in section 5.5 Damage Classification in AS 0484:2023.

5.5.1 General

Damage to racking shall be classified in an escalating hierarchical colour coding system designated by “green”, “amber” and “red” levels of severity (risk). Damage categorised as “green” is deemed acceptable, “amber” is deemed hazardous, and “red” is deemed very serious.

This assessment methodology applies only to damage that produces an overall permanent bend or twist in a member specified in Clauses 5.3.2 to 5.3.4. These limits do not apply to highly localized damage such as dents, buckles, cracks, tears and splits. Components subjected to such localized damage shall be immediately unloaded and replaced unless the advice of a competent person indicates otherwise.

5.5.2 Acceptable damage — “green” level

When the level of damage does not exceed the permissible limits specified in Clauses 5.3.2 to 5.3.4, the racking shall be deemed serviceable and will not require either unit load reduction or immediate unloading.

Damage shall be recorded on the damaged components to indicate that these components have been inspected and the racking is suitable for service until the next inspection when the components will be re-inspected and re-assessed, see Clause 5.2.

Exceeding the “green” risk level shall be considered hazardous or very serious and causes risk to the stability of the racking system.

5.5.3 Hazardous damage —”amber” level

When the level of damage exceeds the permissible limits specified in Clauses 5.3.2 to 5.3.4 by a factor between 1and 2, it is designated “amber” risk level.

The damaged section shall be —

1. clearly identified;
2. unloaded as soon as practicable;
3. isolated; and
4. not reloaded until the necessary repairs have been carried out and the equipment assessed as safe for use.

If repairs cannot be carried out within 30 days, the level of damage shall be escalated to “red” risk (very serious damage) level.

5.5.4 Very serious damage —”red” level

When the level of damage exceeds the permissible limits specified in Clauses 5.3.2 to 5.3.4 by more than a factor of 2, it is designated “red” risk level.

The damaged section and any relevant adjacent sections shall be —

1. clearly identified;
2. immediately unloaded; and
3. isolated

to prevent further use until repairs have been carried out and the damaged section confirmed as conforming to AS 4084.1.

Repairs shall be carried out in consultation with a competent person.

For any modifications and repairs of your racking the standard also states that:

5.6 Modification and repairs

5.6.1 General

Racking systems are highly engineered, thin-walled storage systems requiring specialized installation and repair teams. Only a competent person shall undertake such repairs.

With our extensive racking expertise, our team are classified as competent people and can undertake all your racking repairs and any modifications as needed.

Other Important Information

It’s important to note that AS 0484:2023 also states that:

Section 4 Signage and Documentation

4.1 General

Safe working load (SWL) signs shall clearly display the storage limits for –

1. Unit loads
2. Shelf loads
3. Bay loads

4.2 Signage

4.2.1 Safe working load signs

SWL signs shall be positioned in one or more conspicuous locations on or adjacent to the storage equipment. Signs shall be mechanically secured to the racking structure approximately 2m above the floor level.

The signs shall be permanent, corrosion-resistant and sized not less the A3. Signs shall be indelibly printed using UV stable materials. The colours and symbols used on the sign shall conform to AS1319.

Maximum load action figures shall be in a font at 20mm in height

SWL signs shall display the following information:

1. Permissible working unit load limit
2. Permissible total working unit load limit for each pallet beam level
3. Permissible total working unit load limit for each bay
4. Maximum distance from base plate level to the first beam level and the maximum distance between first and second beam levels
5. Installation tolerance grade of the rack
6. Racking manufacturer’s name
7. Supplier’s name
8. Company responsible for the structural design of the rack
9. Installation date
10. Customer’s name

Signage shall at all times reflect the current configuration. Any modifications to the storage equipment shall require amendment of SWL signage by a competent person.

5.1.3 Specific applications and use of racking

Racking in external environments shall comprise components which are either hot-dip galvanised or manufactured from pre-galvanised coil. If powder coated racing is installed externally, the frequency of formal inspections shall be increase in order to monitor degradation in the protective coating over time.

Components to minimize accidental damage such as upright protectors and rack-end protectors should be installed to protect the racking system. Such components shall be design in accordance with AS4084.1

When it’s time for your yearly audit, the All Storage Systems team is here to help make the process as straightforward as possible by helping you with everything for your yearly audit to any repairs that need completing. Contact our team today to organise your next audit.

Reference:

Standards Australia 2023. Steel storage racking, Part 2: Operation and maintenance, Second edition 2012, Revised in part and redesignated as AS 4084.2:2023.