PALLET RACKING

INSPECTION PROGRAM
PREPARED BY: RYAN GOEDE

MARCH 2009

DIV. OF 1619621 ONTARIO INC.

1378 SANDHILL DRIVE UNIT 7• ANCASTER ONTARIO •L9G 4V5
PHONE: 866.304.9858 • FAX: 905.304.3362
[Link]
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PALLET RACKING INSPECTION PROGRAM

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 a rack 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 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.

An example of a SWL sign is shown in Figure 1.

Safety Sign Regulations

Figure 1: Typical racking SWL
It is now a legal requirement that if a risk or hazard exists,
sign
the employer, after appropriate measures have been taken
Note: Safe Working Load in this case
to reduce or eliminate that risk or hazard, shall use is based upon a unit load of 2500 lbs.
appropriate safety signage to advise, warn and instruct on a standard pallet. Where a large
personnel of the nature of the risks - and take the load is only supported by two points,
necessary measures to avoid or protect against them. refer to supplier to determine whether
It is also a requirement that each employer provides (and the racking is capable of supporting
ensures that each of their employees receives) accurate, that load.
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

components, 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

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:

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

- 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 wooden 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 with post protectors.

7. Damage reporting

Employees are responsible to 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?

Safe working limits beam deflection indicates overloading of the

Are rack load signs posted? racking (the maximum deflection of a the beam
Check that the bays conform to the SWL signs should not exceed L/180 of
provided by the designer / installer, and that the the box sections length). Where two beams
racks have not been altered. 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
replace it or splice a damaged?
new section in. If the Check for obvious
upright is damaged signs of beams being
and is to be replaced, ensure the footplate is also hit by a pallet or
replaced as it will also have sustained damage. forklift. Damaged
Are splices in good condition? beams should be replaced.
Check the condition
of any splices. Ensure
that they are in
accordance with Are beam connectors or safety clips
manufacturer’s missing?
technical Examine beams for damage and replace missing
specification. clips immediately. If clips are regularly being
Out of Plumb Racking dislodged, contact the manufacturer or installer
Is the racking vertical? to determine why they are being dislodged and
Out of plumb racking is implement corrective action.
usually due to incorrect
installation. Contact the Has a beam popped out of its 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
or diagonal braces. See may only show minor damage,
attached table. ensure
welds
are
checked
by a
Are floor anchors
installed? competent person for
Check that floor cracking.
anchors are installed
and are not damaged. Replace as required. If the
floor anchor has been damaged, it is likely that
the footplate will have also received damage and
may need replacing.
Beams
Are beams overloaded?
A large amount of

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RACKING CONCERNS

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 Typical Frame Sections & Measurement Tolerances for Frame
Damage

1.0 m gauge length

10mm

3mm
5mm

View in Frame Direction View in Beam Direction

Typical Beam Section & Measurement Tolerances for Beam

Deflection

Maximum Allowable Deflection Under Load = Beam span

180

Maximum Vertical Deformation, NO Load = Beam span X 20%

180

Maximum Lateral Deformation, NO Load = Beam span X 40%

180

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 INSPECTION REPORT – LOCATIONS

Employee Date:
Names

CODE
1 Requires urgent repairs CODE RED
2 Requires non-urgent repairs CODE YELLOW
3 Suggested modifications
4 Other observations

CODE LOCATION DETAILS NOTES

AUTHORIZED SUPERVISOR/MANAGER PRESENTED DATE

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All measures have been taken to cover all aspects of visual racking inspection in this
report, ideally common sense must prevail, should any damage be questionable in
nature, proper steps should be taken to secure racks & effected area. Further, do not
hesitate to contact myself directly regarding any concerns you may have.

Best regards,

INTERACK SYSTEMS
per. Ryan Goede – General Manager
div. 1619621 Ontario Inc.

DIV. OF 1619621 ONTARIO INC.

1378 SANDHILL DRIVE UNIT 7• ANCASTER ONTARIO •L9G 4V5
PHONE: 866.304.9858 • FAX: 905.304.3362
[Link]

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