Plant & Equipment Inspections
Pallet Racking Inspection Checklist
Routine inspection of pallet racking for upright and beam damage, missing locks, anchor bolts and load signage, using the green / amber / red damage classification in AS 4084. Completed by a trained person, with an annual inspection by a competent racking inspector.
33 checklist items
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Checklist Items
| Item | Pass / Yes | Fail / No |
|---|---|---|
| INSPECTION DETAILS | ||
| Inspection Date | ___________________________ | |
| Warehouse / Site | ___________________________ | |
| Racking Aisles / Bays Inspected | ___________________________ | |
| Racking Type (selective, drive-in, cantilever, etc.) | ___________________________ | |
| Inspected By | ___________________________ | |
| LOAD SIGNAGE & CONFIGURATION | ||
| Safe working load signs displayed on each run | Pass ☐ | Fail ☐ |
| Loads do not exceed rated bay and beam capacity | Pass ☐ | Fail ☐ |
| No unauthorised changes to beam heights or configuration | Pass ☐ | Fail ☐ |
| Pallets in good condition and placed squarely on beams | Pass ☐ | Fail ☐ |
| UPRIGHTS & BRACING | ||
| Uprights: no dents, bends, twists or splits | Pass ☐ | Fail ☐ |
| Bracing: no bent, missing or detached members | Pass ☐ | Fail ☐ |
| Upright protectors / column guards in place | Pass ☐ | Fail ☐ |
| Base plates intact and anchor bolts present and tight | Pass ☐ | Fail ☐ |
| Racking plumb (no visible lean) | Pass ☐ | Fail ☐ |
| BEAMS & CONNECTORS | ||
| Beams: no visible deflection beyond normal or damage | Pass ☐ | Fail ☐ |
| Beam connectors fully engaged, no cracked welds | Pass ☐ | Fail ☐ |
| Beam locking pins / clips fitted on every connector | Pass ☐ | Fail ☐ |
| Decking, mesh and pallet supports in place | Pass ☐ | Fail ☐ |
| SAFETY ACCESSORIES | ||
| End-of-aisle barriers / end frames protected | Pass ☐ | Fail ☐ |
| Back mesh / anti-collapse mesh intact (where fitted) | Pass ☐ | Fail ☐ |
| Row spacers fitted between back-to-back runs | Pass ☐ | Fail ☐ |
| AISLES & OPERATIONS | ||
| Aisles clear and floor in good condition | Pass ☐ | Fail ☐ |
| Floor markings and pedestrian exclusion zones visible | Pass ☐ | Fail ☐ |
| Lighting adequate for forklift operations | Pass ☐ | Fail ☐ |
| DAMAGE CLASSIFICATION | ||
| GREEN (monitor): location and description | ___________________________ | |
| AMBER (repair soon, do not reload once unloaded): location and description | ___________________________ | |
| RED (unload immediately and isolate): location and description | ___________________________ | |
| Red-rated bays unloaded, isolated and tagged | Yes ☐ | No ☐ |
| ACTIONS & SIGN-OFF | ||
| Repairs required and who is responsible | ___________________________ | |
| Repair Due Date | ___________________________ | |
| Last Annual Inspection by Competent Racking Inspector | ___________________________ | |
| Inspector Signature | ___________________________ | |
| Warehouse Manager Signature | ___________________________ | |