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PROC-003cautionv1.0February 2026

Pallet Racking — Loading, Unloading & Inspection Procedure

PROC-003 | Pallet Racking — Loading, Unloading & Inspection Procedure | Version 1.0 | February 2026

Purpose

To ensure pallet racking is loaded, unloaded, and inspected safely, and that racking damage is identified and reported before it causes a collapse.

Scope

All workers who use or work near pallet racking at [YOUR BUSINESS NAME].

Critical Rules

  • NEVER exceed the Safe Working Load (SWL) displayed on the racking load notice.
  • NEVER climb on racking to retrieve goods. Use an approved access method (order picker, elevated work platform, or ladder).
  • Report any racking damage immediately. Damaged racking must be taken out of service until inspected and repaired.
  • NEVER attempt to repair racking yourself. Only approved racking repair contractors may repair damaged racking.

    • Safe Working Loads

    Each racking bay has a load notice showing:

  • Maximum beam load (per pair of beams)
  • Maximum bay load
  • Maximum unit load (per pallet position)

    • Do not exceed these loads. If you are unsure, check with your supervisor before loading.

    Loading Procedure

    Step 1: Check the load notice before loading. Ensure the load does not exceed the SWL. Step 2: Inspect the pallet for damage before placing in racking. Damaged pallets must not be placed in racking. Step 3: Ensure the load is stable and evenly distributed on the pallet. Step 4: Place the pallet centrally on the beams. Ensure the pallet overhangs the beams by no more than 50mm on each side. Step 5: Do not place loads that overhang adjacent pallets. Step 6: Ensure the load does not contact the racking uprights or bracing.

    Unloading Procedure

    Step 1: Inspect the pallet and load before unloading. If the load appears unstable, do not attempt to unload — contact your supervisor. Step 2: Ensure no pedestrians are in the unloading area. Step 3: Remove the pallet carefully, ensuring it does not contact the racking.

    Racking Inspection

    Racking must be inspected:

  • Daily: Visual inspection by operators — look for obvious damage (bent uprights, dislodged beams, leaning).
  • Monthly: Formal inspection by a supervisor using the Pallet Racking Inspection Register (REG-009).
  • Annually: Inspection by a qualified racking inspector in accordance with AS 4084.

    • What to Look For

    Damage TypeAction
    Bent or buckled uprightTake out of service immediately. Do not load.
    Dislodged or bent beamTake out of service. Do not load.
    Missing or damaged safety pinReplace before loading.
    Leaning rackingTake out of service immediately.
    Floor anchor damageReport to supervisor immediately.
    Pallet overhanging beams excessivelyReposition immediately.

    Damage Reporting

    Report any racking damage immediately to your supervisor. Do not wait until the end of the shift. Use the Hazard Report Form (FORM-001) and record in the Pallet Racking Inspection Register (REG-009).

    Damaged racking must be clearly marked "DO NOT USE" and barricaded until repaired. Related Documents: SWMS-008, REG-009, FORM-001 | Legislation: WHS Regulation 2011 (Qld); AS 4084 — Steel Storage Racking