AS 4084 Rack Inspections: Requirements, Inspection Levels and How to Digitise Them

Pallet racking fails quietly. A forklift clips an upright, the steel bends a few millimetres, and the rack keeps holding stock until the day it does not. AS 4084 exists to catch that damage early, and most warehouses know they need a yearly inspection. Far fewer have a system that shows what was found, what was fixed, and which bays have been hit three times since the last audit.

What does AS 4084 cover?

AS 4084 is the Australian Standard for steel storage racking. The 2023 edition is published in two parts:

• AS 4084.1:2023 Steel storage racking, Part 1: Design covers the structural design of racking.
• AS 4084.2:2023 Steel storage racking, Part 2: Operation and maintenance covers installation, tolerances and clearances, operation, inspection, and maintenance. This is the part warehouse operators work with day to day.

AS 4084.2 sets out the need for regular inspection, a formal inspection by a competent person at least every 12 months, a green, amber, and red damage classification, and load signs on racking that show its rated capacity. It also expects any alteration to racking, such as changing beam levels, to be assessed before it is made, because a configuration change alters the rated capacity.

Behind the Standard sits the general duty under WHS laws to provide and maintain safe plant and structures. State regulators, including SafeWork NSW, WorkSafe Victoria, and WHSQ, publish their own racking guidance and enforce it during workplace visits, so check the guidance for each state you operate in.

The three levels of rack inspection

AS 4084.2 sets the 12-month formal inspection as a minimum and asks for regular inspection in between. It does not fix the exact interval for the in-between checks. In practice, most Australian warehouses run a three-level regime, adjusting frequency to forklift traffic, load weights, and damage history.

An unscheduled inspection should also follow any significant impact, a reconfiguration, or an event such as an earthquake.

Green, amber, and red: what each damage level means

• Green: acceptable damage. Damage is within the limits that need action. Record it, photograph it, and monitor it at future inspections.
• Amber: hazardous damage. Action is needed as soon as possible. Do not reload the affected bay once it is emptied, and schedule a repair or replacement.
• Red: very serious damage. Immediate action is required. Unload the affected area, isolate it so it cannot be used, and keep it out of service until it is repaired and cleared by a competent person.

The classification only works if the response is followed through. An amber finding that sits in a spreadsheet for three months is, in practice, a red one waiting to happen.

How to digitise rack inspections

Digital rack inspection is not just a PDF checklist on a tablet. To get the full benefit, set it up like this:

1. Build a location hierarchy. Site, building, aisle, run, bay, and level. Every finding attaches to an exact location, which is what makes trends visible.
2. Tag the racking. A barcode or QR code at the end of each run lets an inspector open the right location in one scan.
3. Use one template per inspection level. A short user check, a fuller monthly template, and the competent person template, each feeding the same location history.
4. Make photos and classification mandatory for damage. Every amber or red finding needs a photo, an annotation, and a classification.
5. Automate the response. A red finding notifies the warehouse manager immediately and creates an isolation task; an amber finding creates a repair action with a due date.
6. Close the loop. Repairs are recorded against the original finding, with a photo of the completed work and sign-off.
7. Review trends monthly. Bays that are hit repeatedly usually point to an aisle width, traffic flow, or training problem that column guards alone will not fix.

How to compare rack inspection software

If you are comparing rack inspection software, the options usually fall into three groups. The table summarises how each handles AS 4084 inspection management.

What to ask in a rack inspection software demo

• Show us an amber finding being recorded with a photo, then the repair being closed against it.
• How are red findings escalated, and to whom?
• Can our external competent person complete their annual inspection in the same system?
• Show the history of one bay across all three inspection levels.
• Does the app work offline in a cold store or a large shed with poor coverage?
• Can findings become maintenance work orders for our repair contractor?

Where Pervidi fits

Pervidi's digital inspection software supports all three inspection levels on one location history, with barcode scanning, annotated photos, and electronic sign-off. Amber and red findings raise corrective actions automatically, with reminders and escalation, and work orders carry the repair through to verified close-out.

Pervidi AI image recognition can assess racking photos for bent or damaged beams and uprights, giving inspectors a second opinion without overriding their judgement. The app runs fully offline, suits transport and logistics and warehousing teams, and is supported from Melbourne.

Frequently Asked Questions

How often does AS 4084 require racking to be inspected?

AS 4084.2:2023 requires regular inspection of steel storage racking, with a formal inspection by a competent person at intervals not exceeding 12 months. Most warehouses also run frequent user checks and monthly routine inspections between the annual inspections.

What do green, amber and red mean in a racking inspection?

Green is acceptable damage that should be recorded and monitored. Amber is hazardous damage needing action as soon as possible, and the bay should not be reloaded once emptied. Red is very serious damage requiring the area to be unloaded and isolated immediately until repaired.

Who can carry out the annual racking inspection?

The annual inspection must be done by a competent person, meaning someone with the training, qualifications, or experience to assess racking. This is often an external racking specialist, though suitably experienced internal staff can also qualify.

What should I look for in rack inspection software?

Look for all three inspection levels on one location history, findings tied to aisle, bay and level, mandatory photos for damage, automatic escalation of red findings, repair tracking to verified close, offline operation, and trend reporting on repeat damage.

Is AS 4084 mandatory?

Australian Standards are not automatically law, but WHS regulators and courts treat AS 4084 as the recognised benchmark for racking safety. Following it is the most practical way to show you have met your duty to keep racking safe.