4 Signs your pallet racking system needs an immediate inspection

As the backbone of your warehouse, your pallet racking system needs attention—especially when it’s trying to tell you something is wrong.

Regular inspections aren’t just about ticking boxes; they’re crucial for safety and preventing significant disruptions.

Today we’re making the unmistakable, urgent signs for an immediate inspection crystal clear, so if they ever come up, you know it’s time to have it all inspected.

The Non-Negotiable of regular Pallet Racking Inspections

Why the fuss about inspections?

The stability and load bearing capacity of your pallet racking system is critical to the safety operation of your warehouse, and the lives of the staff who work in your organisation. This makes regular inspections essential.

Under Australian standards AS 4084-2012 and AS 4084-2023, pallet racking must be inspected at least once a year. But in a busy warehouse, inspections at shorter intervals may also make practical sense.

In your warehouse what should that interval be? When should you call in an on-demand inspection? What factors can influence your decision?

You might expect that Melbourne’s four-seasons-in-one day weather or even the rare threat of seismic activity might be what you most need to look out for as a warehouse manager. But these are not the most common risks that your pallet racking faces. The most common risks are forklift mishaps, overloading, or simply loading the wrong type of goods on to your racks.

With great processes, compliance and staff awareness of when to have things inspected, you’ll keep yourself well ahead of the curve for finding solutions to any pallet racking problems.

What signs should you be looking for?

Sign 1: Unusual Bending or Warping

Metal isn’t invincible.

Over time, beams can bend, and uprights may warp —subtle signs that are easy to overlook.

Add the strain of racks being clipped from time-to-time by pallets during movement and you’ve got a recipe for metal fatigue.

Regular checks for any signs of deformation are key catching issues before they escalate into either a safety issue or significant and unforeseen storage shortages while racking is out of action with no planned downtime for maintenance.

Sign 2: Visible Rust and Corrosion

Rust is more than just ugly; it’s a red flag for structural integrity in moisture prone areas.

Keep an eye out for rust at joint point and along beams—areas where integrity matters.

If the orange menace is present, it’s time to take a closer look.

Sign 3: Damaged or Missing Safety Locks

Safety locks are small but mighty defenders of stability.

Missing or damaged locks might not seem like a big deal, but in areas prone to seismic activity, even as low as Gippsland, they become critical.

Ensuring these locks are intact and functional is essential for maintaining the overall safety and integrity of your racking system.

Sign 4: Uncharacteristic Noises During Operations

Strange creaks or pops? Don’t ignore them.

These sounds can be the first hint of hidden issues, likely loose components or damage not visible during a casual inspection.

Encourage your team to report any unusual noises—they’re often the earliest indicators that something’s amiss.

Wrapping Up: Recognise, React, and Reach Out

Recognising these signs promptly is vital.

It’s not just about having strong warehouse processes, legal compliance or ongoing forklift driver awareness—it’s about ensuring these practices lead to action.

If you spot any of these signs, it’s more than a cue for concern; it’s a call for immediate professional inspection.

Regular training and pallet racking inspections are your first line of defence, but recognising when to call in the experts is equally crucial. If you or your staff see something that could be a potential issue, encourage all staff not to ignore it.

• Stop and take a photo of the issue – you can use this to identify specifically where the problem was spotted and potentially forward it on to experts for a second opinion
• Report it to a supervisor, even if it appears insignificant and regular wear to them
• Build regular visual inspections and walk-arounds as part of your regular safety routines
• Encourage forklift operators to report even minor mishaps to their shift supervisors.
• If there are any issues that you are not sure about, reach out to the experts.

Don’t wait for a minor issue to become a major problem.

Reach out to Erect-A-Rack on 1300 788 916 if you have any questions about your pallet racking system or are seeing some of the signs and would like to book in a service. We’re Melbourne locals and have the expertise and experience to keep you running safely, smoothly and efficiently now and in the future.