Storepro Pallet Racking Inspection

General Purpose
The general purpose of the visual pallet racking inspection, is to identify & report damage to pallet
racking which has the potential to cause danger to personnel who use the racking, as well as the
potential to cause damage to items stored in or around the racking.
This visual inspection consists of evaluating the condition of posts, bracing, beams, base plates,
anchors, safety clips/pins and accessories such as protection and mesh decks.
This visual inspection is conducted at ground level observing the exterior and other reasonably
accessible racking components.
In the event where damaged racking components were identified as requiring immediate
unloading, the site contact will be informed of the specific
racking component and its location.
Disclaimer
This report is submitted on a confidential basis for use by the addressed client.
All findings are based on the facility as it was configured on Inspection.
The inspector has taken care to identify all the racking faults which were visually available on the
day, but due to physical constraints within the facility, we cannot guarantee that all faults have
been identified.
Exclusions
Where racking hasn't been consented we will make no assumption of the weight of products on
the structure, we are assessing visual damage only.
We are unable to comment on seismic capability and / or concrete slab previsions. These
assessments should be made by other 3rd party assessors.
Compliance around fire and egress are also excluded from this report.
Audit Standards
Storepro Solution Ltd visually inspects pallet racking to the AS4084-2023: Maintenance of
Adjustable Pallet Racking standard.
Section 9.2 Inspections.
Inspections shall be carried out on a regular basis, and at least once every 12 months to ensure:
1. The correct application and use of the equipment;
2. The safe working loads are adhered to;
3. The racking installation has not been altered. *
And Examine the below:
1. The extent of damage due to impact since the racking installation.
2. The out of plumb of the racking.
3. For any dislocation and deformation of sections and connections for uprights and beams.
4. Connectors for deformation or signs of cracking at the welds.
Examine base plates and floor anchors damage due to impact. This is assessed in accordance with
clauses 8.3.2 through 8.3.6 and this damage is communicated via report on completion of visual
inspection.
Damages will be classed in a Green, Amber and Red format in accordance with AS4084-2023 5.3 Racking damage

5.3 Racking damage

5.3.1 General

Racking damage from impact, usage or the environment as determined frame informal and formal inspections shall be assessed in accordance with Clauses 5.3.2 to 5.3.9. The extent of impact damage shall be classified in accordance with Clause 5.5.

5.3.2. Uprights

Damage to uprights producing an overall bend shall not exceed 3 mm in the cross-aisle direction and 5 mm in the down-aisle direction when assessed over 1 m.
NOTE 1 Localized bends over a length of less than 1 m may be judged pro-rata to the 1 m limits.
Damage to uprights producing an overall twist, as viewed from directly above the upright member, should not exceed 6°.
NOTE 2 Each 6° of twist is represented by one minute on a virtual analogue clock.
Uprights should not exhibit localized dents, cracks or splits that exceed limits provided by the OEM or a competent person. The advice of a competent person should be sought to determine whether affected uprights should be unloaded.


5.3.3. Frame bracing

For frame bracing, the member deviation from a 1m long straight edge in either plane shall not exceed 10 mm.
NOTE For bracing members less than 1 m in length, damage may be assessed on a pro-rata basis.
Frame bracing should not exhibit localized dents, cracks or splits that exceed limits provided by the OEM or a competent person. A competent person should determine whether affected frames should be unloaded.

5.3.4 Beams

The residual, vertical deformation when unloaded shall not exceed 20 % of the allowed vertical deflection under serviceability loads in accordance with AS 4084-2023.
The residual, horizontal deformation measured at the top or bottom edge of the beam shall not exceed 50 % of the allowed vertical deflection under serviceability loads. If these limits are exceeded, the beam shall be unloaded and advice sought from a competent person.
Beams should not exhibit localized dents, cracks or splits that exceed limits provided by the OEM or a competent person. A competent person should determine whether affected beams should be unloaded.

5.3.5 Connectors

Connectors shall not show visible permanent deformation or signs of cracking of welds. Damage of this type requires that the beam shall be unloaded and advice sought from a competent person.

5.3.6 Connector safety locks

The presence of correctly matched and fitted beam lacking devices shall be checked for during inspection, maintenance and repair. Missing, damaged, dislodged or ill-fitting beam locking devices shall be correctly installed or replaced immediately to prevent accidental dislodgement of beams. A supply of compatible and OEM-approved locking devices shall be stored on site.

5.3.7 Floor fixings

Damage to floor fixings or cracks to the concrete adjacent to the floor fixing shall be documented and advice sought from a competent person. For racking serviced by manually operated mechanical equipment, there shall be a minimum of two undamaged floor fixings per baseplate.

5.3.8 Out-of-plumb racking

Unloaded racking that is out-of-plumb due to impact or the installation not conforming to this document shall not exceed the finished tolerances given in Table 2.2(A), factored by 1.5. When this limit is exceeded, advice shall be sought from a competent person.

5.3.9 Corrosion

Visual inspections of corrosion should use Figure 5.3.9 as a rating guide. Corrosion to racking components should be assessed in accordance with AS 2312.1 and AS/NZS 2312.2 using a tool such as an ultrasonic thickness gauge. Increasing corrosion levels on successive yearly inspections may indicate failure of the coating. If there is doubt about the safety of the system, the advice of a competent person should be sought.

Figure 5.3.9 – Schematic examples for estimating rust percentages

5.4 Unit loads

Unit loads shall meet the following requirements:
(a) All pallets shall be maintained in accordance with AS 4068. Pallets shall be placed onto pallet beams using the method defined by a competent person.
(b) All goods stored on each pallet shall be safely stacked and stable;
(c) Double-stacking of any pallet position shall not be undertaken, including the top-most position, unless the rack system is specifically designed for such loading. The pallet loads themselves shall also be suitable for double-stacking and secured to prevent accidental dislodgement.
(d) Unit load dimensions (width, height, depth) shall be maintained as specified.

(e) Unit load clearances shall be as specified in Clause 2.3 —
(A) in the down-aisle direction;
(B) in the across-aisle direction; and
(C) between units stored on a pallet beam pair.

5.5 Damage classification

5.5.1. General

Damage to racking shall be classified in an escalating hierarchical colour coding system designated by “green”, “amber” and "red" levels of severity (risk), Damage categorised as "green" is deemed acceptable, “amber” is deemed hazardous, and “red” is deemed very serious.
NOTE See Figure 5.5.4 for a visual representation of the damage classification procedure.
This assessment methodology applies only to damage that produces an overall permanent bend or twist in a member specified in Clauses 5.3.2 to 5.3.4. These limits do not apply to highly localized damage such as dents, buckles, cracks, tears and splits. Components subjected to such localized damage shall be immediately unloaded and replaced unless the advice of a competent person indicates otherwise.
NOTE For information on inspection processes or damage classification for equipment outside the scope of this document, refer to the European Materials Handling Federation, the Rack Manufacturers Institute and ANSI MH16.1.

5.5.2. Acceptable damage — “green” level

When the level of damage does not exceed the permissible limits specified in Clauses 5.3.2 to 5.3.4,
the racking shall be deemed serviceable and will not require either unit load reduction or immediate unloading.
Damage shall be recorded on the damaged components to indicate that these components have been inspected and the racking is suitable for service until the next inspection when the components will be re-inspected and re-assessed, see Clause 5.2.
NOTE To indicate that racking or components are suitable for service until re-examined at future inspections, dated coloured adhesive labels may be used.
Exceeding the “green” risk level shall be considered hazardous or very serious and causes risk to the stability of the racking system.

5.5.3 Hazardous damage — “amber” level

When the level of damage exceeds the permissible limits specified in Clauses 5.3.2 to 5.3.4 by a factor between 1 and 2, it is designated “amber” risk level.
The damaged section shall be —
(a) clearly identified;
(b) unloaded as soon as practicable;
(c) isolated; and
(d) not reloaded until the necessary repairs have been carried out and the equipment assessed as safe for use.
NOTE To indicate that the racking is not to be reloaded, dated coloured adhesive labels may be used.
If repairs cannot be carried out within 30 days, the level of damage shall be escalated to “red” risk (very serious damage) level.

5.5.4 Very serious damage — “red” level

When the level of damage exceeds the permissible limits specified in Clauses 5.3.2 to 5.3.4 by more than a factor of 2, it is designated “red” risk level.
The damaged section and any relevant adjacent sections shall be —
(a) clearly identified;
(b) immediately unloaded; and
(c) isolated
to prevent further use until repairs have been carried out and the damaged section confirmed as conforming to AS 4084.1.
Repairs shall be carried out in consultation with a competent person.





Figure 5.5.4 – Flowchart of procedure for damage classification
5.6 Modifications and repairs

5.6.1. General

Racking systems are highly engineered, thin-walled storage systems requiring specialised installation and repair teams. Only a competent person shall undertake such repairs.

5.6.2 Modifications
Racking components shall not be modified without the approval of a competent person.

NOTE 1 Modifications may include physical alterations to uprights, bracing or pallet beams including the welding of additional connectors, bearers or other non-original components.
NOTE 2 Where the manufacturer or supplier is no longer operating and unable to approve the modification, modifications should be carried out by an alternative competent person.
Details of any modifications shall be documented in operating procedures, signs and drawings.
The nature of the load transfer between unit loads and the immediate supporting elements (e.g. uniformly distributed actions or concentrated actions) shall be incorporated in the design of racking modifications.

5.6.3 Repairs

5.6.3.1 Uprights

WARNING — Repairs or alterations to racking uprights are inherently dangerous given their load carrying function.
Where racking uprights have been repaired by splicing, the spliced racking materials shall be installed in accordance with the manufacturer's specifications.
NOTE Where the manufacturer or supplier is no longer operating and unable to approve the modification, modifications should be carried out by an alternative competent person.
There should be at least one beam level above and below the splice. The grade of upright used above the splice should be not less than the grade of upright below the splice. Splices should not be usually positioned at a height less than 1 800 mm.
The following repairs may alter the structural integrity of racking and shall not be permitted:

(a) Repair of a damaged profile that has experienced impact damage resulting in permanent deformation.
(b) Use of a splice kit to strengthen a member where damage to the profile has occurred without approval from a competent person.
(c) Use of any components that are added to the upright to realign it.
If such repairs are identified during inspection, the affected uprights shall be immediately unloaded and advice sought from a competent person.

5.6.3.2 Beams

WARNING — Repairs or alterations to beams are inherently dangerous given their load carrying function.
The following repairs shall not be permitted:
(a) Welds to any area of the beam.
(b) Elements added to the beam to straighten or repair impact damage.

If such repairs are identified during an inspection, the affected beams shall be unloaded immediately and advice sought from a competent person.

5.6.3.3 Bracing

WARNING — Repairs or alterations to bracing are inherently dangerous given their load carrying function.
The following repairs shall not be permitted:
(a) Welds or cuts in a bracing element.
(b) Modification to the bracing pattern.
If such repairs are identified during inspection, the affected frames shall be unloaded immediately and advice sought from a competent person.

5.6.4 Non-original equipment manufacturer components in racking

The integrity of a racking system relies on the performance of its constituent components, the alteration of which can have a significant impact on the load carrying capacity of the entire system.
The use of non-original equipment manufacturer (OEM) components in a racking system can have undesirable and unintended consequences including —
(a) poor fitment of pallet beams into uprights;
(b) variations in the load carrying characteristics; and
(c) subtle variation in frame dimensions and layout.
Non-OEM components shall not be installed in a racking system unless one of the following conditions has been met:
(i) Confirmation from both the OEM and the provider of the non-OEM part that mixing is permissible.
(ii) Testing documentation or calculations confirming that non-OEM components will operate within the design parameters specified by the OEM.
If the addition or mixing of non-OEM equipment is not approved by the OEM, a competent person shall designate the risk category for that application. Competent persons who conduct inspections shall document the OEM-designated risk category in their report and any recommended actions.