The aisle width required for a forklift to operate in racking depends on the type of forklift being used and the racking system configuration. Below are common forklift types and their typical aisle width requirements:

Standard Counterbalance Forklift
• Aisle Width Requirement: 3.5–4.5 metres

Reach Truck
• Aisle Width Requirement: 2.7–3.5 metres.

Very Narrow Aisle (VNA) Forklift
• Aisle Width Requirement: 1.5–2 metres.

Pallet Jacks or Walkie Stackers
• Aisle Width Requirement: 2–3 metres.

Factors Affecting Aisle Width:
1. Pallet Dimensions:
- Aisle width must accommodate pallet length and the turning radius of the forklift.

2. Forklift Load Capacity:
- Larger forklifts with higher load capacities typically require wider aisles.

3. Racking Type:
- Single-deep racking allows for narrower aisles compared to double-deep systems.

4. Safety Clearance:
- Extra space should be added to account for safe operation and load stability.

In Australia, the typical height of a loaded pallet depends on the industry and the type of goods being stored or transported. However, there are general guidelines based on standard practices:

Standard Loaded Pallet Heights:
1. Common Pallet Types:
- Australian Standard: 1,165 mm x 1,165 mm
- Height depends on the load but usually ranges between 1.2 metres (1,200 mm) and 1.8 metres (1,800 mm).

2. Typical Heights by Industry:
- Retail/Consumer Goods: 1.2–1.5 metres.
- Beverages: 1.6–1.8 metres (e.g., cases of bottled water or soft drinks are often stacked higher).
- Building Materials: Variable; may exceed 2 metres but often limited for handling ease.
- Food Products (e.g., boxed goods): 1.4–1.6 metres.
- Frozen/Cold Storage: Often lower, around 1.2–1.4 metres, to ensure stability and easier handling.

Factors Affecting Pallet Height:
1. Warehouse Ceiling and Racking Heights:
- The overall stack height (including the pallet) must be compatible with the storage system and forklift reach.

2. Stability Requirements:
- Loads are often limited by weight and stability for transport and safety.
- Regulatory bodies may impose height restrictions for certain goods.

3. Transport Constraints:
- Maximum truck or container heights often restrict pallet height to around 2.4 metres, including the pallet base, for efficient transport.

In Australia, the frequency of racking audits depends on safety regulations, warehouse usage, and industry standards. Regular inspections are critical to ensure the structural integrity of racking systems, maintain compliance with safety standards, and prevent accidents.

Frequency for Racking Audits:
1. Annually (at Minimum):
- According to AS 4084-2012 (the Australian Standard for steel storage racking), racking systems must be inspected at least once every 12 months by a competent inspector.

2. Additional Inspections (if needed):
- High-traffic warehouses or environments with frequent forklift use may require more frequent audits (e.g., every 6 months).
- After any incidents (e.g., forklift collisions or seismic events), an immediate inspection should be conducted.

3. Weekly or Monthly Visual Checks (In-House):
- Warehouse staff should perform regular visual checks to identify signs of damage or wear (e.g., bent uprights, loose bolts, or misaligned beams).

Key Elements of a Racking Audit:
1. Structural Integrity:
- Assessing beams, uprights, and connectors for damage or deformation.

2. Load Compliance:
- Ensuring the racking adheres to its design load ratings.

3. Anchoring and Stability:
- Verifying racks are securely anchored to the floor and level.

4. Safety Measures:
- Checking for missing safety clips, guards, or load signage.

5. Layout and Clearances:
- Ensuring aisles and access areas meet safety standards.

Consequences of Not Conducting Audits:
• Non-compliance with Work Health and Safety (WHS) laws.
• Increased risk of accidents, product damage, and employee injury.
• Potential legal liabilities and fines.