Skip to main content
MapTrack
Book a demo
Skip to download form

Free pallet racking annual compliance audit (AS 4084)

Free pallet racking annual audit template per AS 4084.2:2023 Section 5. GREEN/AMBER/RED damage classification, load rating verification. Download free.

Download free PDF template

Use in MapTrack →
FreePDFUpdated Oct 2026

Get your free template

Enter your email to download the pallet racking annual compliance audit (AS 4084) as a free PDF. No sign-up required to use it.

G2 rating 4.9 out of 5
Capterra rating 5.0 out of 5GetApp rating 5.0 out of 5Software Advice rating 5.0 out of 5
All MapTrack reviews
Your info is secure. No spam, ever.

These templates are free general guides provided as-is. They do not constitute legal, safety or compliance advice. You are responsible for ensuring any form meets your specific workplace obligations, industry standards and applicable regulations.

G2 rating 4.9 out of 5
Capterra rating 5.0 out of 5GetApp rating 5.0 out of 5Software Advice rating 5.0 out of 5
All MapTrack reviews

Trusted by teams across Australia and New Zealand

We respect your privacy. Unsubscribe anytime.

Updated 26 Oct 2026

Pallet Racking Annual Compliance Audit (AS 4084:2023)

Formal annual inspection by competent person per AS 4084:2023 Section 9

Live form
0 of 40 checks

1. Documentation and Signage

1Load rating signs displayed at each aisle end
2Load configuration diagrams current
3Design certification available
4Modification records (if any)
5Floor plan/layout drawing current
6Safety alert notices displayed

2. Upright Frames

7Uprights plumb (max 1:500 deviation)
8Base plate condition and anchor bolt integrity
9Bracing connections secure
10Bracing members straight (no bowing)
11Front-to-back ties/spacers present and secure
12Surface damage assessment per damage classification table
13Corrosion assessment
14Footing slab condition around base plates

3. Beams and Connectors

15Beam deflection within limits (max L/200 under load)
16Beam connector engagement (safety clips present)
17Beam surface damage or dents
18Beam connector condition (no cracks or deformation)
19Load distribution even across beam pair
20Mixed beam sizes identified and flagged
21Welded vs clip-in connector condition

4. Damage Classification

22GREEN - no action required (damage within manufacturer tolerance)
23AMBER - remedial action needed within 4 weeks (monitor and report)
24RED - immediate unloading required (cordon off bay)
25Damaged components tagged and recorded on register
26Previous AMBER items reviewed for deterioration

5. Floor and Environment

27Floor flatness adequate for forklift stability
28Floor joints not causing rack settlement
29Adequate clearance around rack perimeter
30Lighting sufficient for inspections and operations
31Roof leak or water damage affecting rack components

6. Operational Compliance

32Pallets in good condition (no broken boards in rack)
33Loads not overhanging beam faces
34No side-loading of selective rack
35Rack protection (column guards, end-of-aisle barriers) in place
36Forklift damage reporting procedure in place

7. Seismic Requirements (if applicable)

37Seismic bracing installed per design
38Connections to building structure verified
39Base fixings adequate for seismic zone
40Post-earthquake inspection procedure available

How to use: download the PDF, print or complete digitally on any device.

  • PDF format, ready to print or fill on screen
  • Use as-is or customise to suit your operation
  • Go digital in MapTrack for photos, reminders and audit trails

Or set it up in MapTrack

  • Fill it in on a phone, attach photos to any check
  • Automatic reports and audit trails
  • The same checks as the PDF, ready to configure

Free trial. No credit card. Personal email accepted.

Don't just download it - use it live. Start a free workspace with this pallet racking annual compliance audit (AS 4084) already built, so your crew can run it from a phone.

Jarrod Milford

Jarrod Milford

Co-Founder & Commercial Director

Updated 26 October 2026
Also see:Compliance and inspections →Best inspection software →MapTrack vs SafetyCulture →

Short answer

A pallet racking annual audit records a competent person's formal inspection of every frame, beam, brace, base plate, floor fixing and load sign, with each defect classified and an action set. WorkSafe Victoria says a competent person should complete a formal inspection every 12 months, with informal checks between. AS 4084.2:2023 clause 5.2 covers racking inspections and clause 5.5 damage classification.

Checked against AS 4084.2:2023 (incl. Amd 1:2024) on by the MapTrack templates team. How we check templates

Key takeaways

  • The MapTrack pallet racking annual compliance audit (AS 4084) contains 40 checks across 7 sections. Sections covered: 1. Documentation and Signage, 2. Upright Frames, 3. Beams and Connectors, 4. Damage Classification, 5. Floor and Environment, 6. Operational Compliance, 7. Seismic Requirements (if applicable).
  • WorkSafe Victoria: a competent person should complete a formal racking inspection every 12 months, with informal checks as the manufacturer or competent person recommends.
  • In-service inspection is AS 4084.2:2023 Section 5, with damage classification in clause 5.5; AS 4084:2023 has no Section 9.
  • WorkSafe Victoria classes damage as very serious, hazardous or acceptable, and says unrepaired hazardous damage becomes very serious after 4 weeks.
  • Tag acceptable damage with the date and review it at the next formal inspection.
  • Give the employer a written report of each formal inspection and keep it with the repair records.

Enter your email below to download this pallet racking annual compliance audit (AS 4084) as a ready-to-use PDF.

Used by construction, mining and field service teams

Saunders InternationalMineral ResourcesSupagasHacer GroupMetro TunnelUltrabuilt

What is a pallet racking annual compliance audit (AS 4084)?

A pallet racking annual audit is the formal annual compliance assessment required by AS 4084.2:2023 Section 5, which provides for formal inspections of racking installations by a competent person (clause 5.2.3). This template runs that formal audit at least annually, so check the current edition for the interval it sets. This is distinct from the routine visual inspections performed by warehouse staff. The annual audit involves a systematic structural assessment of every frame, beam, brace, base plate, floor fixing and connector in the racking installation, classification of all damage using the GREEN (minor, monitor), AMBER (significant, action required within 4 weeks) and RED (critical, immediate unloading and isolation required) system, verification of load rating signs against the original design documentation, and issuance of a compliance certificate or non-compliance report.

AS 4084:2023 applies to all selective (adjustable pallet) racking, drive-in racking, push-back racking, pallet flow (live storage) racking and cantilever racking systems in warehouses, distribution centres and manufacturing facilities. The standard recognises that forklift impact damage is inevitable in any operational warehouse, and the annual audit provides a formal mechanism to identify, classify and manage accumulated damage before structural capacity is compromised. A racking collapse can cause multiple fatalities and total loss of inventory. WHS Regulations 2011 impose a general duty on PCBUs to maintain plant (which includes racking) in a safe condition, and the annual audit is the primary means of demonstrating this duty is being met.

Learn more about compliance and inspections in MapTrack.

Get the free template

Enter your email above to download the full pallet racking annual compliance audit (AS 4084) as a PDF.

Download free PDF

Benefits of using this pallet racking annual compliance audit (AS 4084)

  • Structural safety: identifies accumulated damage from forklift impacts, overloading and environmental factors before a rack collapse occurs, which can cause fatalities and millions in losses.
  • AS 4084: 2023 compliance: supports the formal inspection regime in AS 4084.2:2023 Section 5 (clause 5.2.3 Formal inspections), performed by a competent person.
  • Damage classification system: the GREEN/AMBER/RED system provides clear, actionable categories for every piece of damage found, with defined response timeframes for each.
  • Load rating verification: confirms that load signs are displayed, current and consistent with the original engineering design, preventing inadvertent overloading.
  • Insurance requirement: warehouse and contents insurance policies increasingly require evidence of annual racking audits by a competent person as a condition of coverage.
  • Legal defence: a documented annual audit programme provides evidence of due diligence if a racking incident occurs and the PCBU faces prosecution under WHS legislation.

Benefits of digitising forms in MapTrack

When you digitise pallet racking checklists in MapTrack, you get:

  • Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
  • Email the right people when a form is submitted, with an automation you set up.
  • File every completed form against the asset, location or person it covers.
  • Download any completed form as a PDF, with failed answers listed at the top.
  • Fill in forms offline; they upload when the device is back online.
  • Build conditional logic (show or hide questions based on answers).
  • Take pictures or attach photos. Not possible with a paper-based form.
  • Electronic signatures.
  • Edit forms later without reprinting.
  • Set who can view, fill in or edit forms with user roles.
  • Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
  • Assign audits and send reminder emails to the people doing them.
  • Keep every audit, inspection and sign-off against the asset or site it covers.
  • Track corrective actions as work orders from finding to close-out, with each change in the activity log.

Book a demo to see how MapTrack handles pallet racking checklists.

Try MapTrack free

Full access to every feature. No credit card required. Per-asset pricing so you scale as your fleet grows.

Start free trial
  • No credit card required

1-2 days/week saved

“Bloody amazing! We used to spend 1-2 days a week tracking and managing our generators alone.”
Saunders International

Steve McAllister

Asset Coordinator, Saunders International

What to include in a pallet racking annual compliance audit (AS 4084)

This pallet racking annual compliance audit (AS 4084) covers 10 key areas:

  • Site details: warehouse address, client name, audit date, previous audit date, auditor name and qualifications, auditor company.
  • Racking system inventory: number of bays, runs, levels, racking type (selective, drive-in, push-back, pallet flow, cantilever), manufacturer, approximate age.
  • Structural assessment of uprights/frames: plumb measurement, twist, dents, bowing, cracks, weld failures, base plate condition, floor fixing condition.
  • Beam assessment: deflection measurement, connector engagement (minimum 3 safety locks per beam pair), dents, weld failures, surface damage.
  • Bracing assessment: horizontal and diagonal braces, missing braces, bent or disconnected braces, frame ties.
  • Damage classification: every piece of damage classified as GREEN (cosmetic, monitor at next audit), AMBER (significant, repair within 4 weeks, reduced loading may apply), or RED (critical, unload and isolate immediately, engineer assessment required).
  • Load rating verification: load signs present, legible, consistent with design documentation, maximum bay load, maximum beam pair load, maximum unit load.
  • Photographs: photographic evidence of all AMBER and RED classified damage with location reference.
  • Overall compliance statement: compliant, conditionally compliant (with AMBER actions), or non-compliant (RED damage requiring immediate action).
  • Recommendations and next audit date.

How to use this pallet racking annual compliance audit (AS 4084)

  1. Review the previous audit report and prepare the site-specific audit plan.: Obtain the previous annual audit report and review any outstanding AMBER actions or areas of concern. Obtain the original racking design documentation and load rating specifications. Prepare the audit plan including the systematic route through the warehouse to ensure every rack run is assessed. Confirm site access, PPE requirements and any operational constraints.
  2. Systematically inspect every upright frame, starting from a defined origin point.: Work through every upright frame in the installation systematically. Check each frame for plumb (out-of-plumb beyond the AS 4084 tolerance of height/200 is RED). Inspect for dents, bowing, cracks, torn steel and weld failures. Check base plates for damage and confirm floor fixings are intact. Measure and record all damage with location reference and photograph all AMBER and RED items.
  3. Inspect all beams, bracing, connectors and accessories.: Check every beam for deflection beyond span/200 under load (or span/100 unloaded residual deflection). Verify beam-to-frame connector engagement and confirm safety locks are in place (minimum 3 per beam pair). Inspect all horizontal and diagonal bracing for damage, missing components and correct connection. Check row spacers, back stops, pallet supports and other accessories.
  4. Classify all damage using the GREEN/AMBER/RED system and verify load ratings.: Apply the damage classification to every defect identified. GREEN: cosmetic damage within tolerance, monitor at next audit. AMBER: damage exceeding tolerance but not posing immediate collapse risk, requires engineering assessment and repair within 4 weeks, may require reduced loading. RED: damage posing immediate structural risk, requires the bay to be unloaded and isolated immediately pending engineering assessment. Verify load signs against the design documentation.
  5. Issue the audit report with compliance statement, corrective actions and next audit date.: Compile the complete audit report with the site plan marked with all damage locations, photographs of AMBER and RED items, the damage register, compliance status and recommended corrective actions with priority and timeframe. Issue a compliance certificate if no RED or outstanding AMBER items exist. Set the next annual audit date not more than 12 months from the current audit.

In MapTrack, you can automate compliance tracking and audit trails. Each submission is stored as a timestamped PDF against the asset record.

Get the free templateEnter your email above to download the full pallet racking annual compliance audit (AS 4084) as a PDF.Back to download form

How often should you complete this checklist?

AS 4084.2:2023 Section 5 provides for formal inspections by a competent person (clause 5.2.3). This template runs the formal audit at intervals not exceeding 12 months, so check the current edition for the interval it sets. In addition to the annual audit, routine visual inspections should be performed weekly or monthly by trained warehouse staff to identify new damage between formal audits. Any RED-classified damage found during routine checks requires immediate action regardless of the annual audit schedule. In MapTrack, the annual audit is scheduled as a compliance event with automated reminders, while routine inspections are managed as recurring maintenance tasks, ensuring both formal and routine racking safety activities are tracked and documented.

Try MapTrack free

Full access to every feature. No credit card required. Per-asset pricing so you scale as your fleet grows.

Start free trial
  • No credit card required

Frequently asked questions

AS 4084.2:2023 Section 5 provides for formal inspections by a competent person (clause 5.2.3), and this template runs them at intervals not exceeding 12 months. This is the comprehensive structural assessment with damage classification. In addition, routine visual inspections by trained warehouse staff should occur weekly or monthly between formal audits. Both the formal audit and routine inspections must be documented.

GREEN means minor or cosmetic damage within acceptable tolerance that should be monitored at the next audit but requires no immediate action. AMBER means significant damage exceeding tolerance that does not pose an immediate collapse risk but requires engineering assessment, potential load reduction and repair within 4 weeks. RED means critical damage posing an immediate structural risk, requiring the affected bay to be unloaded and isolated immediately pending engineering assessment and repair.

The competent person should ideally be independent of the day-to-day warehouse operation and should have formal training in racking inspection per AS 4084, understand structural assessment principles for cold-formed steel, and be able to apply the damage classification system. In practice, this is a racking manufacturer representative, specialist racking inspection company, or structural engineer with racking-specific training. They must not be an employee involved in warehouse operations.

The annual audit is a formal, comprehensive structural assessment performed by an external competent person covering every component in the installation with engineering-level damage classification. Routine inspections are performed by trained warehouse staff at weekly or monthly intervals, focusing on identifying new damage from forklift impacts and reporting it for assessment. Routine inspections are a supplement, not a replacement, for the annual audit.

RED damage signals an immediate structural risk, so the affected bay or run must be unloaded and isolated from operations before any further work in the area. The auditor records the damage location and classification, the warehouse PCBU arranges engineering assessment of the affected components, and repairs must be completed by a competent installer before the bay is reloaded and a follow-up inspection confirms compliance. WHS Regulations 2011 require that plant identified as unsafe is not used until the hazard is controlled, so leaving RED-damaged racking loaded breaches both AS 4084.2:2023 Section 5 and the general plant duties. The isolation, engineering report, repair record and re-inspection should all be linked to the racking asset to keep a complete remediation history.

Applicable regulatory standards

This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.

  • Steel storage racking, Part 2: Operation and maintenance

    Edition: AS 4084.2:2023 (incl. Amd 1:2024)

    Inspection, damage classification, repair and signage provisions the audit records. In-service inspection is Section 5 of this part.

    • 5.2: Inspections of steel storage racking
    • 5.5: Classification of racking damage
    • 5.6: Modifications and repairs to racking
    • 4.2: Signage requirements for steel storage racking installations

    Standards AustraliaSold by the publisher

  • Pallet racking operation and maintenance

    Edition: WorkSafe Victoria web guidance, page reviewed 8 April 2024

    WorkSafe Victoria guidance: a formal competent person inspection every 12 months and three damage levels with set actions. Guidance, not law.

    • Inspections: Informal inspections at a frequency set by the manufacturer or a competent person, such as daily or weekly, plus a formal competent person inspection every 12 months.
    • Damage action flowchart: Classifies racking damage as very serious, hazardous or acceptable, following AS 4084.2:2023 section 5.5; hazardous damage unrepaired after 4 weeks becomes very serious.

    WorkSafe Victoria

  • Steel storage racking, Part 1: Design

    Edition: AS 4084.1:2023

    Design part of the standard, relevant when a repair or reconfiguration changes the racking from its original design.

    Standards AustraliaSold by the publisher

  • Model Work Health and Safety Regulations

    Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)

    Duties for plant and structures. Model law: check your state's version.

    • Chapter 5: Plant and structures: general duties for plant, duties for registered plant, and registration of plant designs and items of plant.

    Safe Work Australia (drafted by the Parliamentary Counsel's Committee)

  • Model Work Health and Safety Act (Model Work Health and Safety Bill)

    Edition: Model WHS Bill as at 5 December 2025 (includes the Model WHS Legislation Amendment (Incident Notification) 2025)

    Primary duty of care, so far as is reasonably practicable, for the safety of workers and others in the warehouse.

    • s 19: Primary duty of care: a PCBU must ensure, so far as is reasonably practicable, the health and safety of workers and others, including safe plant, systems, training and supervision.

    Safe Work Australia (drafted by the Parliamentary Counsel's Committee)

Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.

Check the current source

Pallet racking annual compliance audit (AS 4084) preview

Pallet racking annual compliance audit (AS 4084) template preview showing fields and layout

The numbers behind this pallet racking annual compliance audit (AS 4084)

The pages below gather the figures behind this kind of check. Each figure on them carries its source and date, so you can quote it in a toolbox talk, a budget case or a board paper without chasing the original report.

Get the free template

Enter your email above to download the full pallet racking annual compliance audit (AS 4084) as a PDF.

Download free PDF

Embed this free template on your website

Run an industry blog, trade association site, or training resource? Drop a preview of this free pallet racking annual compliance audit (AS 4084) straight into your page. The snippet is self-contained, needs no scripts, and links readers back to the full free template.

<div style="max-width:480px;font-family:system-ui,-apple-system,'Segoe UI',Roboto,sans-serif;border:1px solid #E5E7EB;border-radius:12px;padding:20px;background:#ffffff;">
  <p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
  <p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Pallet racking annual compliance audit (AS 4084)</p>
  <ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
    <li style="margin:4px 0;">Site details: warehouse address, client name, audit date, previous audit date, auditor name and qualifications, auditor company.</li>
    <li style="margin:4px 0;">Racking system inventory: number of bays, runs, levels, racking type (selective, drive-in, push-back, pallet flow, cantilever), manufacturer, approximate age.</li>
    <li style="margin:4px 0;">Structural assessment of uprights/frames: plumb measurement, twist, dents, bowing, cracks, weld failures, base plate condition, floor fixing condition.</li>
    <li style="margin:4px 0;">Beam assessment: deflection measurement, connector engagement (minimum 3 safety locks per beam pair), dents, weld failures, surface damage.</li>
    <li style="margin:4px 0;">Bracing assessment: horizontal and diagonal braces, missing braces, bent or disconnected braces, frame ties.</li>
    <li style="margin:4px 0;">Damage classification: every piece of damage classified as GREEN (cosmetic, monitor at next audit), AMBER (significant, repair within 4 weeks, reduced loading may apply), or RED (critical, unload and isolate immediately, engineer assessment required).</li>
  </ul>
  <p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/pallet-racking-annual-audit-as4084" style="color:#071D49;font-weight:600;text-decoration:none;">Pallet racking annual compliance audit (AS 4084)</a> by MapTrack</p>
</div>

Free to reuse, including commercially. This template is published under a Creative Commons Attribution 4.0 licence. Copy it, adapt it, put it on your own site or in your own docs. All we ask is that you credit MapTrack with a link back to this page. The snippet above already includes that credit, so if you use it as-is you’re covered.

Cite this template

Writing about this topic? You’re welcome to quote this checklist. Here’s the wording to use so your readers can find the original.

The MapTrack pallet racking annual compliance audit (AS 4084) contains 40 checks across 7 sections.

Short attribution
MapTrack Pallet racking annual compliance audit (AS 4084), https://www.maptrack.com/templates/pallet-racking-annual-audit-as4084
Reference list
MapTrack. (2026). Pallet racking annual compliance audit (AS 4084) [Checklist template]. Retrieved from https://www.maptrack.com/templates/pallet-racking-annual-audit-as4084

Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/pallet-racking-annual-audit-as4084.

Need to automate compliance tracking and audit trails?

Register every pallet racking in MapTrack, attach digital forms, and get a complete history of every inspection, service and compliance record.

Start free trialBook a demo

Compliance and inspections · All templates · Pricing · Book a demo