Pallet Racking System

APEX pallet racking is designed and manufactured in accordance with AS 4084 – Steel Storage Racking, the Australian Standard governing the design, installation, and use of pallet racking systems. Where required, racking systems can also be engineered to suit site-specific conditions, including wind (AS1170.2:2021) and seismic loads (AS1170.4:2024), based on the installation location and configuration.

APEX works closely with qualified engineers to ensure all racking systems meet applicable safety and compliance requirements.

Yes, pallet racking can be installed outdoors, provided it is designed for external use. All components should be either hot-dip galvanised (HDG) or manufactured from pre-galvanised steel, as these finishes are specifically engineered to resist corrosion and long-term exposure to harsh weather conditions.

Outdoor racking installations must also be structurally assessed for wind and seismic loads, based on the racking configuration and the geographic location of the installation.

In addition, the ground conditions are a critical consideration and are often overlooked. Outdoor pallet racking must be installed on a concrete surface. Alternative substrates such as bitumen or gravel are not suitable. The surface slope should also be assessed, and additional shimming may be required to ensure the racking is level and compliant.

There must be a minimum horizontal clearance of;

• 75mm between the unit load (i.e pallet) and the upright frames
• 100mm between adjacent unit loads on the same beam pair.

The vertical clearances must be maintained between the top of the unit load and the beam level above;

a) where the equipment operator is at ground level and the top;

• Beam levels is positioned below 6m in height=100mm clearance
• Beam level is equal to or above 6m high=125mm clearance

b) where the equipment operator is elevated to the storage level=100mm clearance.

Pallet racking load capacity is determined by the racking configuration, including beam type and length, upright size, bracing, and the number of beam levels. Load ratings are calculated in accordance with AS 4084 and assume correct installation and use.

UDL stands for Uniformly Distributed Load. It refers to the maximum load that can be evenly spread across a pair of beams. Loads that are unevenly distributed or point-loaded may reduce the effective capacity of the racking system.

Pallet racking should be visually inspected on a regular basis as part of routine warehouse operations and formally inspected at least once every 12 months by a competent racking inspector.

Additional inspections are recommended:

• After any forklift impact or visible damage
• Following changes to racking configuration or load requirements
• When operating in high-risk or high-traffic environments

Regular inspections help identify damage early and maintain a safe working environment

If pallet racking is damaged, it should be assessed promptly to determine whether it remains safe to use. Even minor damage can affect load capacity and system performance.

Damaged racking should not be altered or repaired without approval. Depending on the severity, components may need to be isolated, unloaded, repaired, or replaced. Replacement APEX components should be sourced through authorised wholesalers to ensure compatibility and compliance.