The Australian/New Zealand Standard AS/NZS 4084 is the governing framework for pallet racking design, installation, operation and inspection in New Zealand. New Zealand has no separate national standard for steel storage racking; businesses operating pallet racking systems apply the joint standard published by Standards Australia and Standards New Zealand. Compliance with AS/NZS 4084 is a legal obligation for warehouse operators and a recurring focus of WorkSafe NZ audits.
A significant update to the standard was published in May 2023. The 2023 edition replaced AS4084:2012 and introduced mandatory requirements that many warehouse and operations managers have not yet fully incorporated into their compliance programmes. The most consequential change for day-to-day operations is the requirement for an annual racking inspection conducted by an independent, external provider. What the standard requires, who is accountable and what happens during a WorkSafe audit are practical questions this article addresses directly.
What AS/NZS 4084 covers
AS/NZS 4084 is the Australian and New Zealand standard that sets the requirements for steel storage racking systems, covering structural design, manufacture, installation, operation and ongoing inspection. The 2023 edition reorganised the standard into two separate parts, each with a distinct scope.
| Standard | Part | What it governs |
| AS4084.1:2023 | Design | Structural design and engineering requirements for steel storage racking systems |
| AS4084.2:2023 | Operations and maintenance | Operational requirements, maintenance obligations and inspection standards |
AS4084.2:2023 is the part most directly relevant to warehouse and operations managers, as it defines the day-to-day compliance obligations for businesses that own or operate racking systems. The 2023 update replaced the previous standard, AS4084:2012, which had governed the industry since 2012. The 2023 edition introduced several mandatory changes, including stricter requirements for how and by whom annual inspections must be conducted.
Who is responsible for compliance
Under the Health and Safety at Work Act 2015 (HSWA), the Person Conducting a Business or Undertaking (PCBU) holds the primary duty of care for racking compliance. A PCBU must take all reasonably practicable steps to confirm that racking systems on their site are safe for workers and others who may be affected by them. This duty applies to the business operating the racking, not to the racking supplier or installer.
In practice, the accountable parties are typically warehouse managers, operations managers, facility managers and business owners. The obligation does not transfer to a building landlord in a tenanted facility: the business operating the racking system carries the compliance responsibility, regardless of whether it owns the building.
Operations managers who have not previously been the named compliance holder for racking in their organisation should confirm their obligations directly with their employer or legal adviser. WorkSafe NZ guidance on PCBU duties is available at worksafe.govt.nz.
What the standard requires in practice
AS/NZS 4084:2023 sets four principal obligations for racking operators: displaying accurate load notices on each bay, monitoring and classifying racking damage, maintaining written inspection records and providing appropriate training to staff who work with or around racking systems. Each obligation has practical implications for how a warehouse is managed day to day.
Load notices: what they must display
Load signs must be affixed to racking bays and must display the maximum permissible unit load, the beam spacing configuration and any other operational parameters defined by the racking engineer. Notices must be clearly visible, legible and kept accurate at all times. A load notice that no longer reflects the current configuration of a bay is non-compliant, as is a notice that is obscured, damaged or missing.
Businesses that have changed beam spacing, load types or pallet weights since original installation (or since ps1 and ps4 were issued) must review their load notices and have them updated to reflect the current configuration. This is a common gap identified during racking inspections.
Damage classification categories
Racking damage must be assessed and classified by a competent inspector. AS/NZS 4084 applies a three-level classification system to defects identified during an inspection. The classification determines the urgency of the required response and whether racking can continue to be used.
| Classification | Description | Required action |
| Green (low risk) | Minor cosmetic damage with no impact on structural performance | Monitor at next scheduled inspection. No immediate action required. |
| Amber (medium risk) | Damage that affects or may affect structural performance | Repair within a defined timeframe. Loading may need to be reduced until repaired. |
| Red (high risk) | Damage that creates an immediate risk of failure or collapse | Take the affected bay out of service immediately. Do not load until repaired and re-inspected. |
Record-keeping and staff training
Racking operators must maintain written records of all inspections carried out, damage identified, repairs completed and any corrective actions taken. These records represent the primary evidence of compliance during a WorkSafe NZ audit. A business that cannot produce inspection records covering the preceding 12 months has no demonstrable compliance record, regardless of the physical condition of its racking.
AS/NZS 4084 also requires that staff who work with or in the vicinity of racking systems receive appropriate training. This includes forklift operators, warehouse staff and supervisors who are responsible for identifying or reporting damage. Maintaining a record of training provided adds to the compliance evidence available during an audit.
Inspection frequency and what triggers an audit
AS/NZS 4084:2023 requires a formal racking inspection at a minimum every 12 months. This is a mandatory requirement introduced in the 2023 update. Under the previous standard, AS4084:2012, some businesses conducted internal assessments to satisfy this obligation. That approach no longer complies with the standard.
Since the 2023 update, the annual inspection must be carried out by an external, independent provider. A qualified, independent inspector brings objectivity that an internal review cannot replicate and provides a written compliance report that carries the evidential weight required for a WorkSafe NZ audit. Businesses that have been conducting self-assessments should commission an independent inspection to close this compliance gap.
Outside the mandatory annual cycle, a formal inspection is required whenever a significant event or change occurs. The following triggers each require an unscheduled inspection before the racking is returned to normal use:
- A forklift, vehicle or load handling equipment strikes any racking component
- A racking collapse or near-miss incident occurs anywhere in the facility
- Racking is relocated, reconfigured or extended
- Load types, pallet weights or stacking patterns change significantly
- Any structural modification is made to the system, including the addition of accessories
Prompt inspection following a trigger event protects both workers and the business. Damage to a single upright can compromise the structural integrity of an entire bay or run, and the risk is not always visible to the untrained eye.
Consequences of non-compliance
WorkSafe NZ has broad authority to audit warehouses and inspect racking systems as part of its health and safety enforcement activity. During an audit, inspectors may assess the presence and accuracy of load notices, the existence of inspection records covering the preceding 12 months, evidence that the annual inspection was conducted by an independent external provider and the physical condition of racking bays across the facility.
Non-compliance with AS/NZS 4084 can result in WorkSafe NZ issuing an improvement notice, which requires a business to remedy the non-compliance within a specified timeframe, or a prohibition notice, which requires the business to cease using non-compliant racking immediately. In cases where non-compliance contributes to a serious harm incident, businesses face potential prosecution under the Health and Safety at Work Act 2015. Penalties under the HSWA can include fines and, in serious cases involving individuals, imprisonment.
Non-compliant racking can also affect insurance cover. Many commercial insurers require evidence of compliance with applicable standards as a condition of cover for product damage, equipment damage or personal injury claims arising from a racking failure. Businesses should confirm their insurance obligations with their insurer.
WorkSafe NZ’s enforcement guidelines and information on improvement and prohibition notices are available at worksafe.govt.nz.
How Storepro supports AS/NZS 4084 compliance
Warehouse operators that need to meet the external inspection requirement under AS/NZS 4084:2023 can engage Storepro to carry out an independent racking inspection and audit across their facility. Storepro’s inspection and audit service covers damage classification of all bays using the AS/NZS 4084 classification framework, load notice review, identification of configuration or loading changes that require updated signage and a written compliance report documenting findings and recommended actions.
For businesses that identify compliance gaps following an inspection, a WorkSafe audit or a triggering event, Storepro’s racking compliance facilitation service covers the repair, remediation and documentation required to bring a system back into compliance. Storepro operates across New Zealand from offices in Auckland, Waikato, New Plymouth, Wellington and Christchurch, providing local coverage with rapid response.
Businesses planning a new warehouse, upgrading an existing facility or reconfiguring racking to accommodate changes in inventory can engage Storepro at the design stage through its warehouse design and layout planning service, incorporating compliance requirements from the outset rather than addressing them retrospectively.
Storepro conducts independent racking inspections and audits that meet the requirements of AS/NZS 4084:2023 across New Zealand. Request a site assessment or talk to a racking specialist today.