Classic form
Pallet racking inspection checklist with damage ratings
A pallet racking inspection checklist looks at load signs, uprights, beams, beam locks, base plates, guards and bracing, then rates the worst damage green, amber or red. This distribution centre version also counts bays offloaded and lists the repairs with due dates.
The form itself
A static copy of the finished form, exactly as it renders. Nothing here can be filled in or submitted, so read it as a reference and build your own from the button above.
Every field, and what it collects
The complete field list, in the order respondents meet it.
- Aisle and bayShort textRequired
- Load signs present and readable?Single choiceRequired
- Options: Yes · No
- Racking conditionRating gridRequired
- Statements:
- Upright dents
- Upright bends or twists
- Beam deflection under load
- Beam locks in place
- Base plates and anchors
- Column guards
- Bracing members
- Damage categorySingle choiceRequired
- Options: Green · Amber · Red
- Bays offloaded todayNumberRequired
- Photos of the damageFile upload
- Up to six photos. Include one with a tape measure against the dent so the depth can be read.
- Repair actionsTable
- Columns: Location · Damage · Action · Due
- Supervisor signatureSignatureRequired
Location
Damage
What each field on this form collects
The aisle and bay are typed as a range, beside a single choice asking whether load signs are present and readable. The damage grid has seven rows: upright dents, bends or twists, beam deflection, beam locks, base plates and anchors, column guards and bracing. A paragraph explains the three ratings, then a single choice records the worst one and a number field counts the bays offloaded. Up to six photos, a three row table of repair actions with location, damage, action and due date, and the supervisor's signature finish it.
Routine checks and the annual inspection
The Australian racking standard, AS 4084, describes regular visual checks by the warehouse and a detailed inspection by a competent person at least every twelve months. Forklift strikes are what damage racking, and a dent that would fail a bay can be made in a second on night shift and noticed weeks later. A weekly walk by the shift supervisor finds most of it early. WorkSafe Victoria has published an alert about a worker killed by items falling from storage racking, and its guidance on handling stock on shelving and racking covers the loading side of the same risk.
Green, amber and red
The traffic light ratings in the standard turn a judgement into an action. Green damage is within tolerance and is recorded so it can be watched. Amber damage needs repair, and once the bay is offloaded it is not reloaded until fixed. Red damage means offload and isolate the bay immediately. The form asks for the worst rating found, because the action follows the worst damage, not the average. The bays offloaded number makes a red rating visible to operations, since it reduces the pick faces available that day.
How to adapt this form
A cold store adds a row for ice build up on beams and a row for the condition of floor anchors in a freezer slab. A business using longspan shelving for hand picking drops the beam lock row and adds shelf panel condition. A site with an external inspector adds a section for the inspector's report reference so both records sit together.
What makes this form work
The rating follows the worst damage
The paragraph tells the supervisor to choose the worst damage in the location. A bay with six green dents and one red bend is red, and that is what the record says.
A measured photo
The upload asks for one photo with a tape measure against the dent. Depth is what separates green from amber, and a photo with a scale settles it without another walk to the aisle.
Repairs have owners and dates
Three rows of location, damage, action and due turn findings into a short work order. The table has a fixed three rows, enough for one location, which is why each damaged bay gets its own form.
Questions people ask
How often should pallet racking be inspected in Australia?
AS 4084 expects regular inspections by the user, often weekly in busy sites, and a detailed inspection by a competent person at least every twelve months. Inspect after any impact too. The right routine interval depends on how many forklifts work the aisles and how often racking is struck.
What is a red damage rating on racking?
Red means serious damage that needs immediate action: the bay is offloaded and isolated until the damaged part is replaced. Amber means damage that needs repair but allows the existing load to stay while the bay is not reloaded. Green means within tolerance and is recorded for monitoring.
Who can inspect pallet racking?
Routine visual checks can be done by trained warehouse staff such as shift supervisors. The periodic detailed inspection is done by a competent person, usually a racking specialist, who reports against AS 4084. This form is designed for the routine checks and records who did them.
Why does the table only have three rows?
A table field renders the fixed number of rows the form sets and cannot grow while filling it in. Three rows cover the damage in one aisle location. Damage spread across several locations goes on several forms, which also makes each record easier to follow up.
Can the operations manager be told about red ratings straight away?
The email alert add-on sends every submission to one address with the answers in the message, so the manager sees every inspection as it is submitted, red or not. A webhook can pass each one to another system once. The form cannot send only the red ones.
Build your own in about a minute
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Want the steps in the builder? Read Table, grid and upload fields, then Email each inspection to the operations manager. For everything this generator can do, see the form maker.
Written and checked by the OneCraft team. Last checked .