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Racking Inspection SWMS

Racking inspection is essential to preventing catastrophic racking collapse, which can cause multiple fatalities and destroy inventory worth millions of dollars. Inspections must identify forklift impact damage, overloading, incorrect pallet placement, missing safety clips, and structural defects before they progress to the point of failure. Inspectors work at height on elevated platforms and must assess structural elements under load, creating fall and structural collapse risks during the inspection process itself. This SWMS template covers racking inspection procedures compliant with AS 4084 with controls mapped to the Prevention of Falls and Plant codes binding from July 2026.

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Legal Requirements

regulation

WHS Regulation 2025 Part 5.2 — Plant; Part 4.4 — Falls

hrcw category

Work at height greater than 2 metres, structural assessment of loaded racking

code of practice

Prevention of Falls at Workplaces; Managing Risks of Plant in the Workplace (binding July 2026)

section 26a binding

Yes — Both codes binding July 2026. Non-compliance is admissible as evidence of breach.

Hazards

HazardConsequenceLikelihood
Racking structural collapse during inspection of damaged or overloaded baysMultiple fatalities, cascade collapse across multiple aislesUnlikely
Fall from height during inspection of elevated racking componentsFatal fall injuries, spinal cord injury, fracturesPossible
Struck by falling pallets or product dislodged during inspectionCrush injuries, traumatic brain injuryPossible
Forklift-inspector interaction during inspection in active warehouse aislesStruck-by injuries, crushPossible
Manual handling injuries from climbing, reaching, and positioning inspection equipmentMusculoskeletal injuries, falls from laddersLikely

Controls (Hierarchy of Controls)

Conduct inspections by competent persons trained in AS 4084 damage classification (green, amber, red)
Isolate inspection areas from active forklift traffic using barriers and signage
Use elevated work platforms rather than ladders for inspecting racking above 2 metres
Unload damaged racking bays identified as red category before any remediation work commences
Implement immediate isolation procedures for any racking identified with critical damage during inspection
Provide hard hats and high-visibility vests for all personnel conducting racking inspections
Document all inspection findings with photographic evidence and corrective action tracking

Recent Prosecutions

Racking collapse — Victoria$275,000

A multi-bay racking collapse in a warehouse injured three workers after cumulative forklift impact damage was not identified or repaired. The employer had no documented racking inspection program and load ratings were not displayed.

2023 — WorkSafe Victoria Prosecution Database

What Your SWMS Must Include

✓Inspection schedule specifying monthly, quarterly, and annual inspection frequencies
✓Damage classification system aligned to AS 4084 — green (monitor), amber (action required), red (immediate isolation)
✓Isolation procedure for critically damaged racking bays including exclusion zone establishment
✓Fall prevention measures for elevated inspections including EWP requirements above 2 metres
✓Corrective action tracking system with assigned owners, due dates, and completion verification

Need a compliant Racking Inspection SWMS?

Our WHS consultants develop racking inspection programs compliant with AS 4084 including damage classification systems, inspection schedules, and corrective action tracking.

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