Visual Pallet Racking Inspection

Scope, Disclaimer, Exclusions and Audit Standards

1. General Purpose
The purpose of the visual pallet racking inspection is to identify and report damage to pallet racking that may present a risk to personnel using the system, or to goods stored in or around it.
This inspection includes a visual assessment of the condition of:

• Uprights (posts)
• Frame bracing
• Pallet beams
• Baseplates
• Floor anchors
• Beam safety locks / locking pins
• Rack protection systems
• Mesh decks and other accessories

The inspection is conducted from ground level and is limited to the exterior and other reasonably accessible racking components.
Where damaged racking components are identified that may require immediate unloading, the site contact will be informed of the specific racking component and its location as soon as practicable during the inspection process.

2. Disclaimer
This report is submitted on a confidential basis for the sole use of the addressed client.
All findings are based on the condition of the facility and racking system as it was configured at the time of inspection.
While every reasonable effort has been made to identify visible defects and faults, the inspection is limited by site conditions, accessibility, stored product, operational activity and physical constraints within the facility. As such, SCOPE cannot guarantee that all faults or defects present within the racking system have been identified.
This inspection is a visual assessment only and does not constitute a structural engineering certification of the racking installation unless specifically commissioned.

3. Exclusions
Unless specific engineering documentation or certified load information has been provided, no assumptions are made regarding the weight of stored products or the load capacity of the racking structure.
This inspection does not include assessment of:

• Structural design adequacy where racking systems have not been consented or engineered
  Seismic performance or seismic design compliance
• Concrete slab structural capacity or slab reinforcement
• Fire engineering compliance
• Fire protection systems
• Emergency egress compliance

These matters fall outside the scope of a visual racking inspection and should be assessed by appropriately qualified engineers or specialists where required.

4. Audit Standard
SCOPE conducts pallet racking visual inspections in accordance with the relevant provisions of: AS 4084:2023 — Steel Storage Racking
with specific reference to the requirements for inspection, maintenance and damage classification.
In accordance with Section 9.2 – Inspections, inspections should be carried out on a regular basis and at least once every 12 months to confirm:

• Correct application and use of the racking system
• Safe working loads are being adhered to
• The racking installation has not been altered or modified without approval

During inspection, the following conditions are evaluated where visually accessible:

• The extent of damage due to impact since installation
  Racking alignment and out-of-plumb conditions
• Dislocation or deformation of uprights and beam connections
  Connector deformation or cracking at welds
• Damage to baseplates and floor anchors
• Where damage to baseplates or floor anchors is observed, it is documented in the inspection report and referred for review where necessary.

5. Damage Assessment Criteria
Damaged racking components are classified using the Green / Amber / Red risk classification system defined in AS 4084:2023.

5.1 Uprights
Damage to uprights producing an overall bend shall not exceed:

• 3 mm in the cross-aisle direction over a 1 metre length
• 5 mm in the down-aisle direction over a 1 metre length
• Overall twist should not exceed 6 degrees when viewed from directly above the upright.
• Localized dents, cracks or splits that exceed acceptable limits may require the upright to be unloaded and replaced following advice from a competent person.

5.2 Frame Bracing
Deviation of frame bracing members from a 1 metre straight edge in either plane shall not exceed 10 mm.
Bracing members should not exhibit localized dents, cracks or splits beyond acceptable limits. Where such damage is observed, the frame may require unloading and assessment by a competent person.

5.3 Beams
Residual vertical deformation of beams when unloaded shall not exceed 20% of the allowable vertical deflection under serviceability loads.
Residual horizontal deformation measured at the top or bottom of the beam shall not exceed 50% of the allowable vertical deflection.
Where these limits are exceeded, the beam should be unloaded immediately and referred for assessment.

5.4 Beam Connectors
Beam connectors shall not show:

• Permanent deformation
• Cracking of welds
• Distortion preventing correct seating
• Where connector damage is identified, the beam shall be unloaded and referred to a competent person.

5.5 Beam Safety Locks
Beam locking devices shall be checked during inspection.
Missing, damaged or incompatible locking devices must be replaced immediately with OEM compatible devices to prevent accidental beam dislodgement.

5.6 Floor Fixings
Damage to floor anchors or cracking in the concrete adjacent to anchors shall be documented.
For racking serviced by manually operated mechanical equipment there should be a minimum of two undamaged floor fixings per baseplate.

5.7 Out-of-Plumb Racking
Unloaded racking that is out of plumb due to impact or incorrect installation shall not exceed the tolerances specified in AS4084.
Where tolerances are exceeded, advice should be sought from a competent person.

5.8 Corrosion
Where corrosion is visible on racking components it should be assessed using appropriate corrosion rating guidance.
Where corrosion is extensive or progressive between inspections, further assessment may be required.

6. Unit Load Observations
Where visible during inspection, observations may be made regarding:

• Damaged pallets
• Unstable or poorly stacked loads
• Double stacking of pallets where not designed
• Excessive pallet overhang
• Insufficient pallet clearances

These observations are provided as operational safety guidance only and do not constitute a load engineering assessment.

7. Damage Classification

Green – Acceptable Damage
Where damage does not exceed permissible limits, the racking may remain in service. Damage should be recorded and re-assessed at future inspections.

Amber – Hazardous Damage
Where damage exceeds permissible limits by a factor of up to two times, it is classified as Amber risk.
The affected section should be:
Clearly identified
Unloaded as soon as practicable
Isolated
Not reloaded until repaired and deemed safe
If repairs are not completed within 30 days, the damage should be escalated to Red risk.

Red – Very Serious Damage
Where damage exceeds permissible limits by more than two times, it is classified as Red risk.
The affected section shall be:
Immediately unloaded
Clearly identified
Isolated from use
Repairs must be completed in consultation with a competent person before the racking is returned to service.

8. Modifications and Repairs
Pallet racking systems are engineered structural systems and repairs or modifications must only be undertaken by competent persons.

8.1 Modifications
Racking components shall not be modified without appropriate approval.
Examples include:

• Welding additional components to uprights or beams
• Altering frame bracing patterns
• Adding non-original structural components
• Modifying beam connectors

Approved modifications should be documented in drawings, operating procedures and load signage.

8.2 Repairs

• Uprights – Improvised repairs, straightening or welding of impact damaged uprights are not permitted.
• Beams – Welding or adding elements to beams to repair damage is not permitted.
• Bracing – Cutting, welding or modifying bracing members is not permitted.

Where such repairs are identified during inspection, the affected section should be immediately unloaded and referred for engineering advice.

8.3 Non-OEM Components
The structural integrity of racking systems depends on the compatibility of all components.
Non-OEM components should not be installed unless:

• Compatibility is confirmed by the OEM and component supplier, or
• Engineering calculations confirm acceptable performance.

Where unapproved mixed systems are identified, the risk should be documented and assessed by a competent person.