Pallet Racking has transformed the logistics and storage space since its inception in the 1920s – and really took off when Yale & Towne launched the first high-lifting electric forklift in 1923. For all its benefits of storing more stock within a limited building footprint, every precaution has to be taken for pallet racking safety.
The consequences of incorrect assembly, inappropriate loading, and collisions from forklift operators can be nothing short of catastrophic:
Those looking to install new racking or alter their current racking in 2024, including adding additional bays, need to abide by the recently updated Australian Standards: AS4084.1.2023 and AS4084.2.2023
Pallet Racking Safety: Know Your Responsibilities
Many businesses list safety as their top priority or a value of the organisation. In order to live up to that reputation for workplace safety, those using racking systems need to ensure racking is properly installed, regularly inspected and all safety measures are in place.
APEX Racking is designed in compliance with Australian Standards while also being backwards compatible with new standards. Components come with a lifetime warranty for structural stability. Plus, for the peace of mind of those with multinational businesses, APEX Pallet Racking has been manufactured to meet the following global standards:
- Australian Standard, including standards and codes that have since been revised or superseded.
- FEM 10.2.02 European Code of Practice for the design of static steel pallet racks
- AS1250-1981 SAA Steel structures code
- AS1538-1988 SAA Cold-form steel structures code
- SEMA-1980 (UK) Storage Equipment Manufacturers’ Association of Practice for the design and use of static pallet racking
- RMI-1985 (USA) Rack manufacturers’ institute specification of the design, testing and utilisation of industrial steel racks
Warehouse Racking Inspection: A Quick Checklist
If you own or manage an existing warehouse setup, it is your responsibility to ensure regular informal inspections are undertaken by a competent person. Formal pallet racking inspections must be conducted once every 12 months by someone that has worked in the industry as a racking designer, engineer or installer.
The below list is by no means exhaustive but should give you an indication of anywhere where your safety precautions may need to be improved.
- First and foremost, determine the storage equipment is being applied and used as specified
- All footplates must have a minimum of two (2) floor anchors installed. In some cases four (4) may be required. Check with your supplier if unsure
- There are no visible signs of damage to racking uprights, beams, base plates and bracing.
- Check that all beams are fitted with the beam safety locks/pins
- Examine the beam connectors for deformation, signs of welding or cracking and that all are properly fitted into the upright.
- Check that all signage is current, legible and free from damage and obstruction
- Ensure all pallets adhere to the loading limits as indicated on signage
- Adequate lighting, including emergency lighting, is available at all times the warehouse is operational
- Line Marking is installed to indicate foot traffic pathways and forklift operational zones
- Only allowing licensed forklift operators to use lifting machinery, or approved or scissor lift training and tickets
- PPE should be worn by personnel at all times. Additional pieces should be readily available at entry points to the warehouse, including high-viz vests and hardhats
Key Points of New AS4084. 1:2023 Australian Standards
- Where the end frame is adjacent to a trafficable aisle, such as pedestrians, forklifts or other vehicles, must extend past the top load beam by at least 50% of the pallet height
- Upright Protectors of at least 400mm high should be positioned along gangways, on the frame at the end of rows, and at aisle cross-sections
- Racking shall be designed to include Seismic actions in accordance with AS1170.4
Pallet Racking Safety: What Information Needs to be on Signage?
To comply with Worksafe and Australian Standards, all racking needs a load sign, attached to the racking, that displays the layout and applicable loads.
Load signs must be permanent, corrosion-resistant, no smaller than A3 size and font at least 20 mm in height and outline the following;
- The unit load limit
- Beam load limit
- Bay load limit
- Designer’s name
- Manufacturer’s name
- Supplier’s name
- Installation date
- Customers name
- Maximum distance from ground to first beam level
- Maximum distance from first to second beam level
Global Industrial offers a large selection of compliant signage and load information post-inspection and can advise you on what and where these need to be mounted.
How to Ensure Pallet Rack Protection in 2024
One additional way to reduce the chances of harm in a warehouse is to incorporate a mesh-backed system for your pallet rack setup if the run is adjacent to trafficable areas that are accessed by pedestrians, forklifts and other vehicles.
This involves installing stand-off posts and lining them with mesh sheets, which will help prevent items from falling into designated walkways and high-traffic personnel areas. Additionally, custom netting containment systems can be tailored to create a barrier between individual pallet levels.
If you’re looking to install new pallet racking or adjust your current arrangement, remember that AS4084.2.2023 “ Part 2: operation and Maintenance” states that “No changes are allowed to the configuration or usage of the racking without the racking supplier’s authorisation.”
It’s always best to consult with a professional at Global Industrial to ensure you have the most efficient, effective and safe pallet racking system for your warehouse.
