OPERATION AND MAINTENANCE OF PALLET RACKING

INTRODUCTION

When do warehouse storage racks need inspection?

When was the last time you had your warehouse and storage racks independently inspected for integrity and
safety? Would any of your supervisors or line managers respond, "What do I mean "independent"
inspections?

Or -- of greater concern -- would they scratch their heads and ask "What do you mean, rack
INSPECTION?"

Few warehouse operators have aggressive in-house rack inspection programs in place. Forklift accidents,
collisions, dropped or misplaced loads, and other incidents that result in rack damage may or may not get
promptly reported.

But even when a forklift hitting the front end corner of rack #37 South gets reported, a typical management
response never goes beyond "let's go take a look," as if a quick visual inspection alone will confirm that
load limits and structural integrity of the rack have not been affected by the accident.

It's as if, while other hazards "stand out" to otherwise reasonable and prudent supervisors, there often is an
absolute lapse in concern for 100,000 pounds of rack and product collapsing in a pile across the tight
confines of a busy warehouse.

It is especially important to have trained, competent and CONCERNED rack safety personnel when there is
a high degree of activity in the warehouse, where there is the greatest risk of rack damage due to
mechanical materials handling equipment.

When a rack has been struck by a forklift, one of the first priorities should be to identify any unsafe
components in order to reduce the dangers of collapse. Specific precautions and taking damaged segments
out of service immediately may be the only prudent response to prevent possible risk of injury to personnel
caused by continued use of damaged racking.

Rack safety is the employer's morale responsibility and comes with substantial legal liabilities (civil and
criminal). But supervisors should also realize the potential hidden costs of a rack collapse:

 Replacing materials and damaged goods

 Use of temporary storage facilities
 General disruption
 Workers' compensation, general liability and other insurance rate hikes following the loss
 Legal expenses from defending actions resulting from an accident
 Potential HSE fines relating to violations of statutory safety requirements.

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1. Racking design and Materials Handling Equipment

Storage racking for products on pallets should be designed specifically for the size, shape and weight of the
products being stored. The racking design should be compatible with the pallets and the materials handling
equipment in use within the workplace. Aisle width should be matched to the turning circle of the forklift or
other materials handling equipment used to put-away, replenish or pick.

2. Safe Working Loads

Regular inspection of racking should be conducted both in-house and independent to check its integrity,
identify maintenance requirements and to ensure racking is not overloaded.
Do not exceed the Safe Working Limit (SWL) for the unit load or the safe working total load per bay
for the racking.

There should be some means of ensuring that workers using the

racking are aware of its SWL; e.g. having one or more signs in
conspicuous locations, such as at the end of all aisles, which
contain the following information:
a. racking manufacturer's name and trademark
b. safe working unit load
c. safe working unit load for each shelf beam level
d. safe working total unit load for each bay.
An example of a SWL sign is shown in Figure 1.

Safety Sign Regulations

From 1st April 1996 the Health and Safety Regulations 1996 Figure 1: Typical racking SWL sign
Note: Safe Working Load in this case is
came into force. These regulations are based upon EC Directive
based upon a unit load of 1200kg on a
92/58/EEC, a directive for the minimum requirements for the standard pallet. Where a large load is
provision of safety signs and/or health signs at work. only supported by two points, refer to
supplier to determine whether the racking
It is now a legal requirement that if a risk or hazard exists, the is capable of supporting that load.
employer, after appropriate measures have been taken to reduce
or eliminate that risk or hazard, shall use appropriate safety signage to advise, warn and instruct personnel
of the nature of the risks - and take the necessary measures to avoid or protect against them.

It is also a requirement that each employer provides (and ensures that each of their employees receives)
accurate, comprehensible and relevant information regarding safety signage. Also they must ensure that
suitable and sufficient training is given in relation to the meaning of safety signs and the measures needed
to be taken in relation to them.

3. Altering the racking design or components

Any alterations to the racking should be scrutinised by a competent person and should take into account the
effects on the SWL. Operating procedures, signs and drawings should be amended accordingly.

In a broad sense, a competent person is an individual who, by way of training

and/or experience, is knowledgeable of applicable standards, is capable of
identifying storage equipment hazards relating to the specific operation, is
designated by the employer, and has authority to advise on appropriate actions

Physical alterations to uprights, bracings, beams or components, such as welding on additional cleats or
bearers, should not be made.

Replacement of uprights, bracings, beams, clips or other components should be with compatible parts. If not
practicable, an engineering report should be obtained confirming the integrity and SWL of the racking with
these alternative replacement parts.

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4. Operating instructions

Procedures need to be in place within the workplace to ensure that operations are
conducted safely with regard to the racking design, the load and capability of lifting
equipment.

Figure 2 shows a typical sign that can be used to remind managers and employees of
workplace procedures for the safe use of racking.
Operating instructions need to be provided which include but are not limited to:
1. the correct application and use of the equipment
2. the safe working loads to be adhered to
3. prohibitions on unauthorized alterations

d. the requirement to report any damage incurred due to impact so that its effect can be
inspected and assessed (see also Inspection of Pallet Racking below).

5. Goods on Pallet to be stored in racking.

Goods stored on pallets destined for storage are termed Unit Loads. The design of the pallet should take into
account the nature of the goods in the unit load. A change in the pallet design should not be permitted unless
the:

a. racking design is suitable to support the weight of the unit load, and

b. pallet design keys into the racking and so prevents the unit load from being
dislodged.

An assessment of any change to the pallet design should be conducted by a

competent person to prevent storage problems arising, such as:
 changing from timber pallets to post pallets meaning that the legs do not key into racking
 using pallets larger than allowed for in double pallet racking, as they can overlap pallets behind or
push them off their supports
 using pallets smaller than allowed for in the racking, as they can drop through
 using skid pallets in racking without timber decks, as they can drop through.

Boxes, cartons and other such items stored on pallets should not overhang the pallet. Unit loads on upper
levels containing boxes, cartons and other loose loads should be effectively prevented from falling by
wrapping, strapping or by some other means.

6. Collision protection

Bottom portions of those frames that are exposed to possible collisions by forklifts or
other moving equipment should be protected.
The “SEMA Code of Practice for the Use of Static Pallet Racking” gives the following
general guidance:

Clause 8.4 – Rack Protection

“Where necessary, steps should be taken to protect uprights from being struck by
forklift trucks and other vehicles. A first line of defense should be incorporated, such as
renewable column guards or guide rails, which prevent the trucks getting too close to
the main racking structure. Column protection in other areas likely to incur damage
should also be considered”.

7. Damage reporting

Employees should report any damage or near miss occurrences, however minor, to the supervisor so that its
effect on safety can be immediately assessed and the hazard eliminated or risks reduced.

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INSPECTIONS: WHAT TO LOOK FOR?

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Safe working limits Are beams overloaded?
Are rack load signs posted? A large amount of
Check that the bays beam deflection
conform to the SWL indicates overloading
signs provided by the of the racking (the
designer / installer, and maximum deflection
that the racks have not of a the beam should
been altered. not exceed 1/200 of
the box sections length). Where two beams
connect at an upright, the beam connectors
Uprights and footplates should remain reasonably parallel. If racking is
Are uprights damaged? overloaded or has occurred previously, the beam
If the upright shows connectors will form a `V'. This is a quick and
significant damage, or easy guide.
is twisted or contains
splits or cracks, then Are beams damaged?
replace it or splice a Check for obvious
new section in. If the signs of beams being
upright is damaged and hit by a pallet or
is to be replaced, ensure the footplate is also forklift. Damaged
replaced as it will also have sustained damage. beams should be
Are splices in good replaced.
condition?
Check the condition
of any splices. Ensure Are beam connectors or safety clips missing?
that they are in Examine beams for damage and replace missing
accordance with clips immediately. If clips are
manufacturers regularly being dislodged,
technical contact the manufacturer or
specification. installer to determine why they
Out of Plumb Racking are being dislodged and
Is the racking vertical? implement corrective action.
Out of plumb racking is
usually due to incorrect Has a beam popped out of its
installation. Contact the upright?
manufacturer or installer. Check that beams have not
popped out of the upright and are suspended on
one end connector only.

Braces
Are racking braces damaged? Are welds damaged?
Replace bent horizontal If a beam has been hit and may only show minor
or diagonal braces. For damage, ensure welds are checked by a
bracing, the member competent person for cracking.
deviation from a 1 m
long straight edge in
either plane should not
exceed 10 mm.
Floor fixing
Are floor fixings
installed?
Check that floor fixings
are installed and are not
damaged. Replace as
required. If the floor
fixing has been
damaged, it is likely that the footplate will have
also received damage and may need replacing.

Beams

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KILLER RACK!!