Warehouse Racking Regulations in Queensland - AS 4084:2023

Written By Hannah Judd

Understanding AS 4084:2023 and Your Compliance Obligations

Warehouse racking systems are critical structural assets. When they are poorly designed, incorrectly installed, or inadequately maintained, they present a serious safety risk to workers, visitors, and operations. In Queensland, warehouse racking compliance is primarily governed by Australian Standard AS 4084:2023 – Steel Storage Racking, alongside broader workplace health and safety legislation.

This article outlines what AS 4084:2023 requires, who is responsible for compliance, and what warehouse owners and operators should be doing to manage risk.

What Is AS 4084:2023?

AS 4084:2023 is the current Australian Standard that sets out the minimum requirements for the design, installation, operation, inspection, and maintenance of steel storage racking systems including:

  • Pallet racking systems

  • Adjustable pallet racking

  • Drive-in and drive-through racking

  • Cantilever racking

  • High-bay and narrow aisle racking

The standard was updated in 2023 to reflect changes in loading practices, equipment tolerances, inspection regimes, and safety expectations.

While AS 4084 itself is not legislation, it is widely recognised as the benchmark for compliance. In practice, Queensland regulators and courts treat it as the accepted standard of care.

How AS 4084 Interacts With Queensland Law

In Queensland, warehouse racking safety falls under the Work Health and Safety Act 2011 (Qld) and associated regulations. These laws impose a primary duty of care on persons conducting a business or undertaking (PCBUs) to ensure, so far as is reasonably practicable, the health and safety of workers.

Failure to comply with AS 4084:2023 can be used as evidence that a PCBU has not met its duty of care, particularly if an incident occurs.

In simple terms, if racking collapses or contributes to an injury and it does not meet AS 4084 requirements, liability exposure increases significantly.

Key Requirements Under AS 4084:2023

1. Design and Engineering Certification

All racking systems must be designed to safely support their intended loads. This includes:

  • Maximum unit loads per pallet

  • Bay loads and beam capacities

  • Upright frame capacities

  • Allowances for impact from forklifts or pallet handling equipment

Where racking configurations are altered, extended, or relocated, engineering review is required to confirm continued compliance.

2. Correct Installation

Installation must be carried out in accordance with the manufacturer’s specifications and the standard. This includes:

  • Correct baseplate fixing and floor anchoring

  • Plumbness and alignment tolerances

  • Appropriate bracing and beam connections

  • Clear load signage installed and visible

Improper installation is one of the most common compliance failures identified during inspections.

3. Load Signage

AS 4084:2023 requires clear and durable load signage to be displayed on each racking system. Signage must state:

  • Maximum unit load

  • Maximum bay load

  • Maximum beam load

Without signage, workers may unknowingly overload the system, significantly increasing collapse risk.

4. Ongoing Inspection and Maintenance

One of the most critical updates in AS 4084 is the emphasis on routine inspections.

The standard recommends:

  • Regular in-house inspections, typically monthly or quarterly, carried out by trained staff

  • Annual inspections by a competent person, often a structural engineer or qualified racking inspector

Inspections assess damage such as:

  • Bent or twisted uprights

  • Impact damage from forklifts

  • Missing or dislodged beams

  • Floor anchor failures

  • Overloading or incorrect pallet placement

Damage is categorised by severity, with specific timeframes for repair or unloading.

5. Repair, Modification, and Alterations

Racking systems must not be modified without engineering approval. This includes:

  • Adding additional beam levels

  • Changing beam sizes or layouts

  • Relocating racking within the warehouse

  • Welding or straightening damaged components

Temporary repairs or unauthorised fixes are not permitted under AS 4084.

Who Is Responsible for Compliance?

Responsibility does not sit with a single party. Depending on the site, obligations may fall on:

  • Warehouse owners

  • Tenants and operators

  • Facility managers

  • Employers and PCBUs

If you control or influence the use of the racking system, you are likely to hold some level of responsibility under Queensland WHS laws.

Common Compliance Gaps We See

From an engineering and inspection perspective, frequent issues include:

  • Racking installed without engineering certification

  • Load signage missing or incorrect

  • Impact damage left unreported or unrepaired

  • Racking altered to suit operational needs without reassessment

  • No formal inspection regime in place

These issues often go unnoticed until a safety audit, insurance review, or incident occurs.

Why Compliance Matters

Beyond regulatory risk, compliant racking systems:

  • Reduce the likelihood of serious injury or fatality

  • Protect stock, equipment, and business continuity

  • Support insurance and audit requirements

  • Demonstrate due diligence and proactive risk management

In many cases, early inspections and minor repairs prevent far more costly failures later.

AS 4084:2023 sets a clear and practical framework for managing warehouse racking safety in Queensland. Compliance is not just about ticking a box. It is about ensuring that a critical structural system performs safely throughout its lifecycle.

If you operate or manage a warehouse, regular inspections, clear documentation, and professional engineering advice are essential steps in meeting your obligations and protecting your people.

Hannah Judd
Next

Future Proofing Your Project Management Career