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ARTICLE
Rack up the safety checks
25 January 2013
Regular inspections of storage equipment are essential to ensure employee safety, explains Alex Ashcroft, installation & projects manager,Construction Group UK It is a requirement of the HSE, as detailed in 'Health &
Regular inspections of storage equipment are essential to
ensure employee safety, explains Alex Ashcroft, installation
& projects manager,Construction Group UK
It is a requirement of the HSE, as detailed in 'Health & Safety in Wholesale and Retail Warehouses', that racking and shelving storage systems must be installed, used and maintained correctly to protect against injuries.
Similarly it is essential that warehouse staff work in a safe environment where equipment is regularly checked for damage and defects.
If a racking system collapses it can lead to major injury or even death. Racking is made from relatively light components and consequently is susceptible to damage. Any damage will reduce its loading capacity.
Eventually the racking will collapse even when it is within specified safe load limits. Prevention is always better than the cure, and is less expensive.
Periodic rack safety audits make good business sense and are a key component of every warehouse's successful planning and operation.
In general terms, storage equipment comes in two categories - shelving and racking.
Shelving is for pedestrian picking, handloaded applications and as such, under normal use, sustains little damage. Racking, however, is constantly being loaded and unloaded with mechanical handling equipment and is more susceptible to damage.
The HSE and The Storage Equipment Manufacturers Association (SEMA) give the following areas to look at for potential problems: Beams: Missing beam locks/pins; bent/ deformed beams when unloaded; dislodged beam connectors; damaged beam profiles.
Uprights: Front impact damage (limit 5mm); Side impact damage (limit 3mm); damaged/ missing braces; damaged/missing floor fixings.
The limits quoted are measured by using a simple 1m long straight edge held against the racking upright. The damage/deflection is measured in the centre of the straight edge.
It is essential that companies use qualified forklift truck drivers who should only be expected to work within their capabilities.
Not only is it necessary to use the right type of truck intended for a particular installation, it is important to ensure that the layout of the racking system provides good access for that vehicle with adequate aisle widths free from obstruction.
Pallets and decking can be a potential cause of damage. Broken or poor quality pallets can cause premature beam failure by putting outward pressure on the inside faces of the beams. Dropping heavy goods on to decking, overloading, or forcing items into place can cause them to weaken and become unstable.
Other rack accidents occur when the structures are not properly secured to the floor slab or when unsecured beams are dislodged. Improper loading, either by exceeding capacity constraints or not placing the pallet's squarely on the decking can cause it to either tip off the front or back of the rack or to push another pallet off an adjacent rack in a double-deep situation.
Protecting racking Collisions between forklifts and racking are a relatively common occurrence in a busy warehouse.Where racking is likely to be struck by vehicles it should be protected with column guards or rail systems. Semi-flexible, moulded plastic guards, such as Rack Armour or Protect-it products, are quickly attached to racking or building columns to form a protective bumper. They reduce the power of fork truck impact that can easily damage the structural integrity of racks and floors leading to health and safety issues and expensive repairs. They are designed to fit all standard European racking uprights and are easily fitted around the feet of racking systems and secured by Velcro straps. They deflect any impact energy away from the racking to provide effective protection against most collision damage.
In addition to upright protection, rackend protection, guide rails and tunnel guards there is netting and wire mesh backing and safety signs, which include safe working load markings and maintenance signs.
Maintenance contracts When there is a high degree of activity in the warehouse, it is especially important that trained and competent rack safety personnel regularly inspect the racking system. When a forklift has struck a rack, 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 racking 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 moral responsibility and comes with substantial legal liabilities (civil and criminal).
An audit will help in ensuring the number of incidents is kept to a minimum. It will examine the set up of the warehouse and help identify a pattern of operation that may be contributing to rack damage, or that additional training, signage, or upgraded rack protection systems are required.A racking maintenance contract with a respected company ensures compliance with health and safety regulations. The Workplace (Heath, Safety & Welfare) Regulations 1992, states: "The workplace and the equipment, devices and systems to which the regulation applies shall be maintained in an efficient state, in efficient working order and in good repair." The PUWER Regulations states that audit period should not exceed 12 months. Section 5 states "…equipment to be maintained in an efficient state, in efficient working order and in good repair" and that repairs, modifications, maintenance and servicing are restricted to competent personnel.
The contracted company will arrange for trained technicians to make a site visit and inspection to provide a detailed assessment of the storage system and layout. A report will be sent to the customer highlighting any damaged, missing or badly fitted component and detailing any replacements and repairs needed. Such contracts give peace of mind to the employer and provide a written history for health and safety inspectors and insurance companies.
It is a requirement of the HSE, as detailed in 'Health & Safety in Wholesale and Retail Warehouses', that racking and shelving storage systems must be installed, used and maintained correctly to protect against injuries.
Similarly it is essential that warehouse staff work in a safe environment where equipment is regularly checked for damage and defects.
If a racking system collapses it can lead to major injury or even death. Racking is made from relatively light components and consequently is susceptible to damage. Any damage will reduce its loading capacity.
Eventually the racking will collapse even when it is within specified safe load limits. Prevention is always better than the cure, and is less expensive.
Periodic rack safety audits make good business sense and are a key component of every warehouse's successful planning and operation.
In general terms, storage equipment comes in two categories - shelving and racking.
Shelving is for pedestrian picking, handloaded applications and as such, under normal use, sustains little damage. Racking, however, is constantly being loaded and unloaded with mechanical handling equipment and is more susceptible to damage.
The HSE and The Storage Equipment Manufacturers Association (SEMA) give the following areas to look at for potential problems: Beams: Missing beam locks/pins; bent/ deformed beams when unloaded; dislodged beam connectors; damaged beam profiles.
Uprights: Front impact damage (limit 5mm); Side impact damage (limit 3mm); damaged/ missing braces; damaged/missing floor fixings.
The limits quoted are measured by using a simple 1m long straight edge held against the racking upright. The damage/deflection is measured in the centre of the straight edge.
It is essential that companies use qualified forklift truck drivers who should only be expected to work within their capabilities.
Not only is it necessary to use the right type of truck intended for a particular installation, it is important to ensure that the layout of the racking system provides good access for that vehicle with adequate aisle widths free from obstruction.
Pallets and decking can be a potential cause of damage. Broken or poor quality pallets can cause premature beam failure by putting outward pressure on the inside faces of the beams. Dropping heavy goods on to decking, overloading, or forcing items into place can cause them to weaken and become unstable.
Other rack accidents occur when the structures are not properly secured to the floor slab or when unsecured beams are dislodged. Improper loading, either by exceeding capacity constraints or not placing the pallet's squarely on the decking can cause it to either tip off the front or back of the rack or to push another pallet off an adjacent rack in a double-deep situation.
Protecting racking Collisions between forklifts and racking are a relatively common occurrence in a busy warehouse.Where racking is likely to be struck by vehicles it should be protected with column guards or rail systems. Semi-flexible, moulded plastic guards, such as Rack Armour or Protect-it products, are quickly attached to racking or building columns to form a protective bumper. They reduce the power of fork truck impact that can easily damage the structural integrity of racks and floors leading to health and safety issues and expensive repairs. They are designed to fit all standard European racking uprights and are easily fitted around the feet of racking systems and secured by Velcro straps. They deflect any impact energy away from the racking to provide effective protection against most collision damage.
In addition to upright protection, rackend protection, guide rails and tunnel guards there is netting and wire mesh backing and safety signs, which include safe working load markings and maintenance signs.
Maintenance contracts When there is a high degree of activity in the warehouse, it is especially important that trained and competent rack safety personnel regularly inspect the racking system. When a forklift has struck a rack, 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 racking 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 moral responsibility and comes with substantial legal liabilities (civil and criminal).
An audit will help in ensuring the number of incidents is kept to a minimum. It will examine the set up of the warehouse and help identify a pattern of operation that may be contributing to rack damage, or that additional training, signage, or upgraded rack protection systems are required.A racking maintenance contract with a respected company ensures compliance with health and safety regulations. The Workplace (Heath, Safety & Welfare) Regulations 1992, states: "The workplace and the equipment, devices and systems to which the regulation applies shall be maintained in an efficient state, in efficient working order and in good repair." The PUWER Regulations states that audit period should not exceed 12 months. Section 5 states "…equipment to be maintained in an efficient state, in efficient working order and in good repair" and that repairs, modifications, maintenance and servicing are restricted to competent personnel.
The contracted company will arrange for trained technicians to make a site visit and inspection to provide a detailed assessment of the storage system and layout. A report will be sent to the customer highlighting any damaged, missing or badly fitted component and detailing any replacements and repairs needed. Such contracts give peace of mind to the employer and provide a written history for health and safety inspectors and insurance companies.
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