Pallet Racking Installation SWMS
SWMS template for pallet racking installation. Covers Selective racking install, uprights, beams. 8-state AU coverage, CIH-reviewed editable DOCX, available as an instant download.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Pallet racking installation covers the installation of steel pallet racking in warehouses — erecting the uprights, beams and bracing of the racking system to AS 4084, which is then loaded with pallets. The defining hazards are the work at height building the tall racking, the stability of the partially built racking, the heavy racking components and manual handling, and the plant used to install and load it. This document is written on the basis that pallet racking installation is carried out by competent installers with the work-at-height, stability, manual-handling and plant controls in place.
Pallet racking installation is carried out to AS 4084 for the design, installation and use of the steel racking, with the work at height controlled, the partially built racking kept stable and braced, the heavy components handled safely, and the racking plumbed, anchored and braced correctly. Where the racking is installed at a height creating a risk of a person falling more than two metres, it is high risk construction work. The work at height, the racking stability, the manual handling, and the plant are the considerations. This document coordinates the work-at-height, stability, manual-handling and plant controls so the pallet racking is installed safely.
Hazards identified
9 hazards covered, sorted by priority.
Falls from height erecting the tall racking
Crush from collapse of partially built or unbraced racking
Musculoskeletal and crush injury from the heavy racking components
Racking failure from inadequate plumb, anchorage or bracing
Crush and collision from the forklifts and plant
Impact injury from falling components and tools
Falls where fall prevention is not provided
Failure from inadequate floor fixing and base condition
Collapse from overloading or incorrect use after installation
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Engineering: provide fall prevention for the work at height building the racking — work platforms, elevating work platforms or a harness-based system where higher-order controls are not practicable — to the managing the risk of falls Code of Practice.
- 2Engineering: keep the partially built racking stable and braced as it is erected, so it cannot collapse, and complete the bracing, plumb and anchorage to AS 4084.
- 3Engineering: use mechanical aids — trolleys, dollies, stair-climbers, pallet jacks and lifting equipment — and team lifting for the heavy and awkward loads, and manage the manual-handling and awkward-posture hazard with correct technique and the hierarchy of controls for hazardous manual tasks.
- 4Engineering: plumb, anchor and brace the racking correctly to AS 4084 and the manufacturer's design, with the floor fixing and base condition adequate.
- 5Administrative: have forklifts and powered mobile plant operated only by the holder of the appropriate High Risk Work Licence — an LF licence for a forklift truck or an LO licence for an order-picking forklift — to AS 2359, with the operator competent for the specific plant.
- 6Engineering: control falling components and tools with exclusion below and securing, and separate the plant and pedestrians.
- 7Administrative: install the racking to its design and rated capacity, with load signage, so it is not overloaded or incorrectly used after installation.
- 8Administrative: where the racking is installed at a height creating a risk of a person falling more than 2 metres, prepare a SWMS for the high risk construction work before it commences.
- 9Administrative: all workers must hold the competencies and licences required for the work, including a High Risk Work Licence for forklift operation, a heavy vehicle driver licence for heavy vehicles, and any dangerous goods or other training required.
- 10Administrative: conduct a pre-start toolbox talk covering the day's work, identified hazards, traffic and plant movements, required PPE and emergency procedures, and record attendance in the consultation section.
- 11Administrative: consult workers and any health and safety representatives on the work and its risks, record the consultation, and keep this document available at the workplace.
- 12PPE: high-visibility clothing, eye protection where required, gloves appropriate to the task, hearing protection where required, and Class I or Class II safety footwear with protective toecap to AS/NZS 2210.3.
- 13Administrative: review and update this SWMS whenever the work scope changes, after any incident or near miss, when a worker or health and safety representative raises a concern, when new hazards are identified, or at minimum every 12 months.
Applicable Codes of Practice
The design, installation and use requirements for steel pallet racking systems.
Fall-prevention controls for work at height, such as installing tall racking or order-picking at height.
Controls for the forklifts, conveyors, compactors, lifting and mobile plant used in the work, including guarding and safe operation.
The control of the manual handling and awkward postures of the work, including heavy and awkward loads, bins and items.
The general construction work duties where the work is construction work, such as installing racking at height.
High-Risk Construction Work triggered
Installing tall pallet racking involves work at height where a person could fall more than 2 metres, which is high risk construction work requiring a SWMS before the work commences.
This is work that, in the circumstances described, is high risk construction work — where there is a risk of a person falling more than 2 metres — so a SWMS must be prepared before the work commences, kept readily accessible, reviewed as necessary, and given to the principal contractor if one is appointed. The work is also carried out in connection with the relevant plant, manual handling, traffic and, where heavy vehicles or dangerous goods are involved, the Heavy Vehicle National Law and Chain of Responsibility and the Australian Dangerous Goods Code, with the controls for the specific hazards applied. A failure in this work can cause serious crush, fall, traffic or chemical injury, and breaches of the relevant legislation and the primary duty of care under the model WHS Act, together with the Chain of Responsibility duties, are actively enforced, with offence categories running from failure-to-comply through to reckless conduct, and the most serious breaches carrying imprisonment for individuals. Body-corporate maxima are substantial and indexed; the current maximum follows the prevailing schedule of the responsible regulator.
Who this is for
- →Installers erecting pallet racking.
- →Racking and warehouse fit-out contractors.
- →Warehouse and logistics businesses installing racking.
- →Warehouse operators and PCBUs.
- →PCBU safety managers and supervisors coordinating the work-at-height, stability and plant controls.
What you receive
- ✓Editable Microsoft Word document (.docx) fully compatible with Microsoft Word 2016 and newer, Google Docs, and LibreOffice Writer.
- ✓Title page with editable fields for PCBU name, ABN, site or depot address, task or route description, and document revision date.
- ✓Hazard register with the pallet racking installation hazards — each with a documented consequence, inherent risk rating on a 5x5 likelihood-consequence matrix, hierarchy-of-control measures, and residual risk rating.
- ✓Pallet racking prompts referencing AS 4084 and the falls Code of Practice, a work-at-height section, a racking-stability and bracing section, and a manual-handling and plant record.
- ✓Licensing and competency prompts for the forklift, heavy vehicle, dangerous goods and other work, and a plant pre-operational and inspection checklist where relevant.
- ✓Worker consultation record per the model WHS Act consultation duty and a worker sign-on register (blank, expandable).
- ✓Applicable legislation and Codes of Practice schedule pre-populated for the model WHS jurisdiction with a state-variance reference table covering the harmonised states, plus Victoria, and the Heavy Vehicle National Law where relevant.
- ✓Emergency procedure template and a revision log.
Worked example
Installers are engaged to erect steel pallet racking in a warehouse. Because the racking is tall, fall prevention is provided for the work at height — work platforms, elevating work platforms or a harness-based system where higher-order controls are not practicable — to the managing the risk of falls Code of Practice, and a SWMS is prepared where the racking is installed at a height creating a risk of a fall more than two metres. The partially built racking is kept stable and braced as it is erected, so it cannot collapse, and the bracing, plumb and anchorage completed to AS 4084. The heavy racking components are handled with mechanical aids and team lifting. The racking is plumbed, anchored and braced correctly to AS 4084 and the manufacturer's design, with the floor fixing adequate. The forklifts are operated by licensed operators, and falling components controlled with exclusion below. The racking is installed to its design and rated capacity with load signage. The installation is completed safely, and the records retained.
Related legislation
- Model Work Health and Safety Act — primary duty of care; the duty to consult workers; the reckless-conduct offence; and notifiable-incident provisions, as enacted in each jurisdiction.
- Model Work Health and Safety Regulations — the plant, hazardous manual tasks, hazardous chemicals and High Risk Work Licence provisions, and the Section 291 high risk construction work and SWMS duties where applicable, as enacted in each jurisdiction.
- The Heavy Vehicle National Law and the Chain of Responsibility, the National Transport Commission Load Restraint Guide 2018, and the Australian Dangerous Goods Code, apply to heavy vehicles and the transport of dangerous goods, alongside the model WHS framework, and are administered by the National Heavy Vehicle Regulator and the state and territory dangerous goods regulators.
- Forklift operation requires a High Risk Work Licence (LF or LO class) under each state and territory's licensing scheme, and heavy vehicle driving requires the appropriate heavy vehicle driver licence; dangerous goods drivers require dangerous goods licensing and training.
- Victoria operates under the Occupational Health and Safety Act 2004 and the Occupational Health and Safety Regulations 2017, with the plant, manual handling, hazardous chemicals and high risk construction work provisions applying in place of the model instruments, alongside the Dangerous Goods Act 1985.
Frequently asked questions
Is pallet racking installation high risk construction work?
Installing tall pallet racking involves work at height, and where the racking is installed at a height creating a risk of a person falling more than two metres, it is high risk construction work requiring a SWMS before the work commences. Fall prevention is provided and the SWMS prepared where the height triggers it.
How is racking collapse prevented during installation?
The partially built racking is kept stable and braced as it is erected, so it cannot collapse, and the bracing, plumb and anchorage completed to AS 4084. Keeping the partially built racking stable and braced, and completing the bracing and anchorage, prevents a collapse during installation.
What standard governs pallet racking?
AS 4084 governs the design, installation and use of steel storage racking, and the racking is plumbed, anchored and braced to AS 4084 and the manufacturer's design, installed to its rated capacity with load signage. AS 4084 is the standard for the racking installation and use.
What is the manual-handling hazard?
The racking components — uprights, beams and bracing — are heavy, so handling them can cause musculoskeletal and crush injury, and they are handled with mechanical aids and team lifting. Managing the manual handling of the heavy racking components is a key consideration in racking installation.
Who installs pallet racking?
Pallet racking installation is carried out by competent installers to AS 4084, with the work-at-height, stability, manual-handling and plant controls, and a SWMS where the work is at a height creating a fall risk more than two metres. The racking is erected and braced safely and installed to its rated capacity.