Guide to Safe Maintenance
of Pallet Racking
Pallet Racking usually sits in a busy and potentially dangerous environment. We recommend scheduled inspections
of your racking to make sure it is safe and conforms to the Australian Standard and local Worksafe requirements.
This Unirack guide will help you to understand the inspection of your racking. It shows how to spot damage or to
evaluate whether an accident will require your racking to be replaced or repaired.
Unirack offers FREE Racking Inspections upon request. We also offer TWO Free 6 monthly inspections for all
new installations. In most cases, we can rectify small problems on the spot.
Call your local outlet to arrange an inspection today.
S.W.L. (Safe Working Loads) signs explained
1000 1000 Total weight capacity
per pallet space.
Total capacity of load for uneven
or oversized [Link]
loads reduce overall capacity.
Please refer to manufacturer’s
guide to calculate likely
capacity changes. 2000 Total capacity
for each beam level.
Total capacity of bay. 9000
Quick guide to correct load placement
Step by Step Guide - Beams
Beam Height
To maintain the highest load capacity of your
uprights, the first level of beams should be no
higher than 1500mm.
Measure the load height of the pallets stored
in the lower bay, then add 200mm to allow for
adequate clearance. If you require the first beam
level higher, the overall load capacity of the bay
will be reduced. Refer to manufacturers guide.
The first beam level should be at 1500mm or below
Beam Damage
A visual inspection of beams should be
conducted every 6 months. Check the beam
length (on all 4 faces) for dents, then check the
connectors where the beam meets the upright.
Any damaged beams should immediately be
replaced. Their load capacity can be significantly
compromised by seemingly small imperfections. It
is also important to check the beam slots on the
upright. If they have been damaged or are
misshapen, the beams should be repositioned to
an undamaged slot. Damaged beams Check beam slots
should be replaced. on the upright.
Overloading Beams
Never overload the beams. Always refer to the Calculate Allowable Deflection
S.W.L (Safe Working Load) signage. A beam that
has been previously overloaded may also be unsafe.
Measure the "deflection" of a beam when loaded
and unloaded to work out whether a beam is still (mm)
safe to use at the prescribed SWL. See right.
Attach String Line
Measure
Example: With a standard 2591mm beam, an unloaded beam should
show no more deflection than 3.24mm (2591 divided by 800). A loaded
beam should not show deflection of more than 14.4mm (2591mm
divided by 180).
Step by Step Guide - Uprights
Out of Plumb
Upright frames must be upright! Not out of Check your “Out of Plumb” distance
plumb ([Link] out of vertical or true). And as level over larger heights
as possible. If you wish to test over a larger area
then use the formula below.
To check this, place a 1m spirit level on an
unloaded racking upright. Move the level until it measurement length (mm)
Tolerance =
reads "plumb" and measure the distance between mm 500
the base of the spirit level and the upright. To
keep within tolerance this distance must be less
then 2mm. (1000mm divided by 500 gives you Example, for a 3658mm upright, the
2mm) “out of plumb” distance at the base of
the upright should be less than 7.3mm.
3658mm
= 7.3
500
Bracing Damage
Damage to bracing occurs in normal
warehouse operations. It should be actively The maximum Bracing Damage in
looked for during routine inspections. either direction or plane over a
1000mm distance = 10.0mm
If damage is within an acceptable
tolerance, then the racking may continue to The allowable damage for bracing less
be used (see diagram and discussion right). than 1000mm in length is pro-rata the
above.
Bracing that is damaged must be replaced Eg 5.0mm over 500mm or 7.5mm over
immediately and cannot be done while 750mm.
uprights are loaded.
Upright Damage
Front To Back Damage Tolerance
Damage to the uprights can occur in 2 ways:
The maximum Upright Damage due to impact in the direction of the
Side-to-Side or Front-To-Back (more common).
bracing over a 1000mm distance = 3.0mm
If the damage is within acceptable tolerances,
If the damage is localised, the allowable damage for a distance less
the uprights can still be used. In most cases, if
than 1000mm in length is pro-rata the above.
there is only one damaged section and it is less
Eg 1.5mm over 500mm or 2.25mm over 750mm
than 3mm over a 1000mm section of the upright,
you can still use the upright.
Side To Side Damage Tolerance
The maximum Upright Damage due to impact in the direction of the
beams (Side to Side) over a 1000mm distance = 5.0mm
If the damage is localised, the allowable damage for a distance less
than 1000mm in length is pro-rata the above.
Eg 2.5mm over 500mm or 3.75mm over 750mm
Please Note: Where possible alwasy test over 1000mm span
Pedestrian Safety
What can you do?
Pedestrians have right of way in your
warehouse.
Pedestrian walkways must be clearly marked
and signposted. Paint it bright and they will
follow! Train your staff where to walk and keep
your local Worksafe Authority happy.
If walkways are close to racking, wiremesh backing panels should be installed. This
prevents items being dislodged from above by a forklift operator on the other side.
Remember, forklifts and pedestrians don't mix! Make sure your signage is visible and
clear.
Keeping your racking checked and maintained will keep your
workers safe from unnecessary accidents and injury!
Recommend You Check Your Racking EVERY 6 Months
WE CAN DO YOUR SAFETY CHECKS . . . RING TODAY.
CONTACT YOUR NEAREST UNIRACK OUTLET
Melb - North
1/5 Brand Drive, Thomastown
(03) 8376 9460 (03) 8376 9461 (03) 8376 9462
- North - South
For more info go to [Link]