EXPERT THIRD PARTY

REPORT
2024 DSample
Layout
Project Registered ID - PRJ3RW7Y8BDS | Inspection Ref. ID - TPA9BIEC7KPM

For :

XXX
Hariyala, Gujarat, India

rXXX1@[Link]

86XXXXXX0X9

Submitted By :

Salt Design & Infra Services Pvt Ltd

Pune, Maharashtra, India

adityat@[Link]

9538694002
Inspection Details

Project Registered ID PRJ3RW7Y8BDS

Inspection Ref. ID TPA9BIEC7KPM

Inspection Start Date 2024-09-10

Inspection End Date 2024-09-13

Report Issue Date 16th September 2024

Export Third Party Report For RXXXX

Signature & Stamp

Name Ganesh Sanap Rohit Baraskar

Designation Inspector Inspector

Qualification

Certification

Report Created In : RAMS | [Link]

TABLE OF CONTENTS
1. Definition And References 1

2. Executive Summary 2

3. Report Summary 4

4. Introduction 6

5. Scope And Objective 7

6. Methodology 9

7. Site Information 11

8. Layout And Design 13

9. Inspection Findings 14

10. Technical Inspection 16

11. Element Wise Assessment 18

12. Rack Health Statistics 19

13. Rack Health Layout 20

14. Reported Issue 21

15. Generalized Issue 74

16. Testing Procedure 75

17. Structural Analysis 83

18. Risk Assessment 88

19. Recommendation 91

20. Maintenance Strategy 94

21. Compliance And Standard 97

22. Conclusion 99

23. Annexture A 455

24. Annexture B 456

 DEFINITIONS & REFERENCES
I. Damage

Damage in racking systems refers to any physical harm or deterioration that impacts the structural integrity
or functionality of the components

II. Defect

Defects in racking systems refer to flaws or imperfections in the components that may affect their
performance or safety.

III. Bay

In the context of pallet racking systems, a bay refers to the space between two vertical frames where the
pallets are stored. Each bay typically consists of multiple horizontal beams that support the pallets.

IV. Frame

Frames are the vertical components of a racking system. They provide the primary structural support and
consist of two upright columns connected by bracing.

V. Issue Categorization

After the inspection, the racking system was categorized into three risk levels:

Green: Areas where no damage or minimal damage was observed, allowing for continued use with no
further action required.

Amber: Areas where moderate damage was identified, requiring remedial work. Unloading of the rack may
be necessary for repairs.

Red: Areas with significant damage exceeding industry standards. These areas were immediately
offloaded and isolated from future use until repairs are completed.

Standards Used for Rack Inspection and Maintenance

EN15620 - Steel static storage systems — Adjustable pallet racking — Tolerances, deformations and
clearances.

EN 15629 - Steel static storage systems - Specification of storage equipment.

EN 15635- Steel static storage systems — The application and maintenance of storage equipment.

EN15512 -Steel static storage systems — Adjustable pallet racking systems — Principles for structural
design.

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 EXECUTIVE SUMMARY
I. Racking System Overview

In this section, we present a comprehensive overview of your current racking system, outlining key
statistics related to the number of racks, frames, uprights, beams, and bracings.

Category Quantity

Rack Rows 14

Bays 220

Frames 234

Uprights 468

Beams 2400

Bracings 4290

II. Inspection Findings

The following table categorizes inspection findings using a color-coded system (Red, Amber, Green) to
denote the severity of issues identified during the inspection.

Category Number of Issues

Green 85

Amber 137

Red 5

**Count includes generalized issue count

III. Compliance

This section outlines the compliance of your racking system with the relevant standard. The reference
standard used is EN Standard, and the compliance is assessed based on key clauses. Out of 13 clauses,
compliance has been achieved in 9 clauses.

IV. Functional Problems

We have identified specific functional problems within your racking system that may impact the safety of
the racks. These issues could increase the likelihood of racks getting damaged. We observed 4
generalized issues.

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 V. Testing Summary

The testing procedures conducted on your racking system and their finding are tabulated below:

Test Sampling Test Advanced Test Acceptable Non-acceptable

Conducted Conducted results results

Verticality Test 234 22 22 0

Beam Deflection - 47 46 1
Test

*** Sampling test is conducted on all front side uprights using Spirit Gauge instrument, bubble on the gauge if found outside the limit once
placed on upright are shortlisted and then advance test are carried out on shortlisted uprights

The detailed findings and results of each test are elaborated in the report, providing a comprehensive
understanding of the structural integrity and performance of the racking system under various conditions.

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 REPORT SUMMARY
I. Element Wise Issue

Element Name Damage Defect

Red Amber Green Total Count Red Amber Green Total Count

Beam 0 1 24 25 0 7 12 19

Upright 0 13 26 39 4 6 9 19

Bracing 0 8 5 13 0 0 0 0

Baseplate 1 4 4 9 0 2 4 6

II. Issue Wise Count

Sr. No. Issue Name Red Amber Green Total Count

1 Upright-Damage 0 13 26 39

2 Beam-Damage 0 1 24 25

3 Bracing-Damage 0 8 5 13

4 Beam-Paint Coating Defect 0 0 12 12

5 Upright-Paint Coating Defect 0 0 9 9

6 Baseplate-Damage 1 4 4 9

7 Beam-Lack of Safety Locking Pin 0 7 0 7

8 Upright-Missing Bolt at U-B Connection 0 4 0 4

9 Upright-Twisted Upright 4 0 0 4

10 Baseplate-Loose Nut 0 0 4 4

11 Upright-Loose Nut at U-B Connection 0 2 0 2

12 Baseplate-Tilted Anchor Bolt 0 2 0 2

III. Generalized Checklist

Sr. No. Issue Name Red Amber Green Total Count

1 Toe guard has tyre marks - (Loose fixing ) 0 4 0 4

IV. Safety Accessories Count

Sr. No. Issue Name Sub Issue Type Red Amber Green Total Count

1 Toe Guard Loose Fixing 0 92 0 92

2 End Protector Damaged Fixing 0 0 1 1

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 V. Vertical Alignment Test

Total Test Above 100% 80% - 100% 50% - 80% Below 50%

22 0 2 5 15

VI. Beam Deflection Test

Total Test Above 100% 80% - 100% 50% - 80% Below 50%

47 1 10 20 16

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 INTRODUCTION

This report presents a thorough examination of the safety, structural integrity, and compliance aspects of
the pallet rack system within .The inspection incorporates comprehensive testing procedures to ensure a
holistic evaluation of the pallet rack infrastructure.

Background

Pallet racks, as integral components of warehouse logistics, are essential for efficient inventory
management. The impetus for this inspection is rooted in the fundamental need to ensure a secure
working environment, protect valuable inventory, and align with industry safety standards and regulations.

Scope of Inspection

This inspection encompasses scrutiny of frames, beams, connections, and load-bearing elements.
Specialized tests such as verticality assessments, beam deflection analyses, member thickness
evaluations, and load capacity assessments are employed to provide nuanced insights into both structural
soundness and functional performance.

Objectives

The primary objectives of the inspection are:

Identify structural deficiencies, damages, or deviations from safety standard EN Standard within the pallet
rack system.

Evaluate the system's compliance with industry-specific safety standard EN Standard,ensuring that
structural components meet or exceed recommended guidelines.

Verifying the load-bearing capacities as well as to find the effect of daily operations on racking system,
utilizing specialized tests to understand how the system performs under varying conditions.

Stakeholder Collaboration

This inspection's success is underpinned by effective collaboration with key stakeholders, including facility
managers, safety officers, and maintenance personnel. Transparent communication and coordinated
efforts have played a pivotal role in facilitating a comprehensive and well-informed assessment.

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 METHODOLOGY

Pre-Inspection Planning

Conduct a thorough review of facility layouts, rack configurations, and historical maintenance records to
inform the development of a tailored inspection plan.

Stakeholder Coordination

Engage in open communication and collaboration with key stakeholders, including facility managers,
safety officers, and maintenance personnel, to gather insights into specific concerns, historical issues, and
operational considerations.

RAMS Integration

Integrate the Rack Asset Management System (RAMS) into the inspection process by setting up and
digitizing the racking system to leverage its capabilities for real-time data capture, documentation, and
future trend analysis.

Detailed Visual Inspection

Conduct a visual inspection of all pallet rack components, systematically assessing frames, beams,
connections, and load-bearing elements for signs of wear, damage, or structural anomalies.

Testing Procedures

Implement a series of tests, including verticality assessments, beam deflection analyses, member
thickness evaluations, and load capacity assessments, to evaluate both structural soundness and
functional performance under varying conditions.

Data Collection

Utilize RAMS for real-time data collection, ensuring accurate and consistent recording of inspection
findings, measurements, and photographic documentation.

Safety Compliance Checks

Conduct assessments to verify the pallet rack system's compliance with safety standard , with a specific
emphasis on identifying any discrepancies that might impact safety.

Identification of Deviations

Document any deviations from safety standards, industry best practices, or facility-specific guidelines,
highlighting areas where corrective actions are necessary to align with safety protocols.

Risk Assessment:

Performe a comprehensive risk assessment based on the inspection findings, categorizing identified risks
by severity and potential impact to prioritize corrective actions.

Recommendations Development

Synthesize inspection findings and risk assessments to develop actionable recommendations for
immediate and long-term maintenance, repairs, and improvements.

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 Reporting

Prepare a detailed report using RAMS documenting all inspection procedures, findings, and
recommendations. The report includes a comprehensive analysis of structural integrity, safety compliance,
and potential risks.

Post-Inspection Collaboration

Engage in post-inspection discussions with stakeholders to review findings, discuss recommendations,

and foster collaboration in implementing corrective actions and long-term maintenance strategies. Granting
limited access to the RAMS warehouse user portal for visualizing data and tracking recommendations.

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 INSPECTION FINDINGS
GENERAL INFORMATION

Project PIN: PRJ3RW7Y8BDS

Inspection By: Salt Design & Infra Services Pvt Ltd

Start Date: 2024-09-10

End Date: 2024-09-13

No. of Inspectors: 2

Layout Name: XXXX

No. of Racks: 8 - XXXX

No. of Frames: 234

VISUAL INSPECTION

During the visual inspection stage, drawings were prepared based on the site input and used as a
reference for marking up defects and damages. The following issues were inspected during the visual
examination of the pallet rack system:

Element-Specific Inspections:

1. Baseplates:

Inspected for proper anchoring, presence of all bolts, and any signs of damage or misalignment.

Checked for missing or loose nuts and bolts, and for any settlement or misalignment affecting the stability.

2. Uprights:

Examined for physical damage such as dents, bends, and compromised paint coatings.

Assessed for structural integrity and proper vertical alignment.

3. Beams:

Inspected for signs of damage such as dents, twisting, and improper alignment.

Checked for the presence and condition of safety locking pins and other securing mechanisms.

4. Bracings:

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 Evaluated for physical damage and correct installation.

Ensured that all bracing members were present and properly secured.

5. Tie Beams and Run Spacers:

Inspected for any signs of damage or stress.

Checked for proper fastening and alignment.

6. Safety Accessories:

Toe guards, end protectors, Unit stoppers and mesh barriers were inspected for missing, loose, or
damaged fixings.

7. Flooring Joints:

Checked for signs of settlement, cracks, and unevenness.

After the inspection, the racking system was categorized into three risk levels:

Green: Areas where no damage or minimal damage was observed, allowing for continued use with no
further action required.

Amber: Areas where moderate damage was identified, requiring remedial work. Unloading of the rack may
be necessary for repairs.

Red: Areas with significant damage exceeding industry standards. These areas were immediately
offloaded and isolated from future use until repairs are completed.

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 Technical Inspection
Rack Wise Assessment

Rack Name Red Amber Green Other Total Issue

L9. 0 21 7 0 28

L1. 0 16 11 0 27

L13. 0 19 6 0 25

L2. 0 10 10 0 20

L3. 0 9 9 0 18

L4. 0 12 6 0 18

L8. 0 12 6 0 18

L5. 0 9 3 0 12

L10. 1 4 6 0 11

L14. 0 4 7 0 11

L6. 0 6 4 0 10

L7. 0 6 4 0 10

L11. 3 1 4 0 8

L12. 1 4 2 0 7

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 Severity Wise Assessment

Classification Condition Total Issue

Green 85

Amber 133

Red 5

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 Element Wise Assessment

468 58 2400 44
Total Upright Total Issues Total Beam Total Issues

35 19 4 36 8 0
Green Amber Red Green Amber Red

4290 13 468 15
Total Bracing Total Issues Total Baseplate Total Issues

5 8 0 8 6 1
Green Amber Red Green Amber Red

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 Rack Health Statistics

Frame Wise Assessment

Health Indicators

Red 4 Frame
No. of Frames
Amber 109 Frame

Green 30 Frame

Healthy 91 Frame

For a general understanding, the issues found are shown in relation to the adjacent frame. From the graph
above, we can determine the number of frames affected by the issues, indicating how many frames are
unhealthy due to the presence of these issues.

Rack Wise Assessment

Health Indicators

Red 3 Rack
No. of Racks
Amber 11 Rack

Green 0 Rack

Healthy 0 Rack

For a general understanding, the issues found are shown in relation to the rack. From the graph above, we
can determine the number of racks affected by the issues, indicating how many racks are unhealthy due to
the presence of these issues.

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Rack Health Layout

Elementwise Damages
Baseplate 15 Unit Stopper 0 Pallet 0 Tie Beam 0

Bracing 13 Safety Accessories 93 Splice 0

Beam
Report 44 | [Link]
Created In : iNODE RAMS Run Spacer 0 Upright 58 20
 Structural Analysis

Objective

The primary objective of carrying out structural analysis for the rack system is to check the Utilization Ratio
under current loading conditions. This ratio helps evaluate the capacity of various structural members based
on actual loads, ensuring that the racking system remains within the safety limits.

Process

Modeling in STAAD-Pro: Using STAAD-Pro software, a detailed model of the racking system ’s structural frame
is generated. This model replicates the real-world conditions and loads imposed on the racks.

Analysis for Gravity Loads: The model is subjected to gravity load analysis to evaluate the impact of dead
and live loads on the racking system. This includes checking for deformations, stresses, and the structural
integrity of the system.

Reference Codes

The following codes have been used in the analysis of the racking system:
IS 801: Code of practice for use of Cold-formed Light Gauge Steel Structural Members

Material Grade & Properties

Minimum guaranteed yield strength of 350 MPa.

Modulus of Elasticity: 2.1 x 10⁵ N/mm²
Density of Steel: 78.5 kN/m³
Poisson's Ratio: 0.34

Load Types and Load Combinations

Dead Load (DL): The permanent load associated with the racking system and its structural components.
Live Load (LL): The variable load imposed by stored materials, equipment, or temporary loading conditions
Load Combinations:DL + LL

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 Staad Pro Model Photos

Plan View of Racks Side View of Racks

3D View of Rack System

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Structural Analysis Result

Sr. Descriptio Size Load UDL UDL Span Actual Allowable Allowable Utilization Limiting Actual Section Allowable
No. n Considered Front Back (M) Stress Stress After Ratio Utilization Allowed Capacity Load kg
Beam Beam (N/mm2) (N/mm2) deduction Ratio to Stress
(KN/m) (KN/m) (N/mm2) 0.9 (N/mm2)

1 85 X - - - - 131.084 231 184.8 0.71

65 X
Doyle Asia
Upright 1 1.9
MM

2 100 2000 3.704 3.704 2.7 210.384 231 231 0.91

Doyle Asia X 45
Beam 1 X 1.5
MM

3
Doyle Asia
25 X - - - - 6 231 231 0.026
Bracing 1 20 X
1.5
MM

4 Godrej 110 - - - - 104 231 184.8 0.56

Upright 1 X 80
X 2.2
MM

5 Godrej 105 2000 3.704 3.704 2.7 173.15 231 231 0.75
Beam1 X 50
X 1.5
MM

6 Godrej 30 X - - - - 7.284 231 231 0.032

Bracing 1 30 X
1.3
MM

The above table are the results from STAAD Pro Model. As seen from the above table, Utilization Ratio is less than 1 for both OEMs (Doyle Asia & Godrej)

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RISK ASSESSMENT
The risk assessment section of the report analyses potential hazards and their associated risks identified
during the pallet rack inspection. It categorizes risks based on severity and potential impact, providing a
foundation for prioritizing corrective actions. Here's a detailed breakdown.

1. Identification of Risks:

Structural Risks

Identified risks pertaining to structural integrity include weakened frames and compromised connections. A
total of 223 issues have been identified, each with its own risk percentage concerning the structural integrity
of the racking system.

Safety Compliance Risks

Risks associated with non-compliance with safety standards include the non-complied issues from the
compliance and standard section of the report. Adhering to compliance as per industry standards is crucial to
mitigate the possibility of future damages. It is noteworthy that a total of 4 have been identified as not
complied, underscoring the importance of addressing these issues promptly and comprehensively

2. Severity Assessment:

Red Severity Risks

Risks categorized as Red severity include those with the potential for catastrophic failure, immediate safety
hazards, or significant damage to the pallet rack system. A total of 5 such issues have been found.

Amber Severity Risks

Risks of Amber severity may pose safety concerns or have the potential to impact the system's performance
over time, requiring attention but not immediate action. A total of 133 such issues have been found.

Green Severity Risks

Risks of green severity may have minimal immediate impact but could develop into larger issues if not
addressed over an extended period. A total of 85 such issues have been found.

3. Potential Impact Evaluation:

Operational Impact

In the event of any incident involving the listed red issues, a major impact on operations is anticipatedDuring
the rectification activity, it is imperative to remove the load from the beams, resulting in operational impact.

Safety Impact

The issues categorized as red pose a potential risk, thus contributing to a safety impact on worker safety No
critical issues were found; therefore, there is no safety impact- if no red issues.

Financial Impact

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 Considering the financial implications of identified risks, including repair costs, potential inventory damage,
and operational downtime. No critical issues were found; therefore, there is no financial impact- if no red and
amber issues.

4. Prioritization of Risks:

Immediate Action Required

Risks categorized as red severity with immediate safety concerns that demand urgent attention and
immediate corrective actions.

Short-Term Action Required

Risks of amber severity that require timely intervention to prevent deterioration and potential safety hazards
in the short term.

Long-Term Action Recommended

Risks of green severity that can be addressed through long-term maintenance strategies without immediate
urgency.

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RECOMMENDATIONS
The recommendations section outlines actionable steps based on the inspection findings and risk
assessment. These recommendations aim to address identified issues, enhance safety and structural
integrity, and establish a proactive maintenance plan. The content is organized for clarity and prioritization of
actions. Here's a detailed breakdown.

1. Immediate Actions

Structural Repairs

Address identified structural deficiencies promptly through necessary repairs, replacements, or

reinforcements. In total, numbers of issues have been found that require repairs and replacements, the
strategy for which is detailed in the following section of the report.

Safety Compliance Measures

Implement immediate modifications to ensure compliance with safety standards

2. Short-Term Actions

Reinforcement and Upgrades

Initiate reinforcement measures for beams, frames, and connections to enhance overall structural stability

Training Programs

Conduct training programs for personnel involved in pallet rack operations, emphasizing safety protocols and
load management.

3. Long-Term Maintenance Plan

Scheduled Inspections

Establish a regular inspection schedule to monitor the condition of pallet racks, identify potential issues early,
and address them proactively.

Preventive Maintenance Procedures

Develop and implement preventive maintenance procedures, including rust prevention, protective coatings,
and routine component checks.

Load Capacity Monitoring

Integrate load capacity monitoring as a routine practice, assessing changes in storage patterns and adjusting
capacities accordingly.

4. Structural Enhancements

Consideration of New Technologies

Explore and consider the integration of new technologies to monitor health of the racking system

Expert Structural Analysis

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 Engage structural engineering experts to conduct a comprehensive analysis and recommend enhancements
for long-term structural robustness.

5. Collaboration with Stakeholders

Continuous Communication

Maintain open communication with all stakeholders, providing regular updates on the progress of
recommended actions and addressing any concerns.

Collaborative Decision-Making

Engage in collaborative decision-making with facility managers, safety officers, and maintenance personnel
to ensure a shared understanding of priorities and timelines.

6. Documentation and Reporting

Comprehensive Reporting

Document all implemented actions and changes, providing a comprehensive record for future reference and
analysis.

Photographic Documentation

Continue photographic documentation of structural changes and maintenance efforts to track improvements
over time.

7. Continuous Monitoring and Review

Utilization of RAMS

Continue utilizing the Rack Asset Management System (RAMS) for continuous monitoring, data analysis,
and trend tracking.

Periodic Review of Recommendations

Conduct periodic reviews of the implemented recommendations to assess their effectiveness and adapt
strategies based on changing conditions.

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MAINTENANCE STRATEGY
In this section, we present the rectification suggestions provided by our expert inspector for the
identified issues within your racking system. The information is segregated according to the
manufacturer and specific racking elements.

Manufacturer - Godrej

Baseplate Rectification

Issue Details Severity Specification According to Manufacturer No. Of Elements Rectification Activity Closing Date

Deformation Green 125*180*5.1 2 Under Observation 16 Sep 2025

Loose Nut Green - 1 Repair 16 Sep 2025

Beam Rectification

Issue Details Severity Specification According to No. Of Rectification Activity Closing Date
Manufacturer Elements

Dent Amber 105*50*1.5 1 Replace 16 Oct 2024

Lack of Safety Locking Amber - 1 Other - Install the safety locking pin as As soon as
Pin soon as possible possible

Paint Coating Defect Green 105*50*1.5 12 Repair 16 Sep 2025

Dent Green 105*50*1.5 12 Under Observation 16 Sep 2025

Damaged Beam Green 105*50*1.5 6 Under Observation 16 Sep 2025

Connector Tabs

Horizontal Bracing Rectification

Issue Details Severity Specification According to Manufacturer No. Of Elements Rectification Activity Closing Date

Bend Amber 30*30*1.3 1 Replace 16 Oct 2024

Dent Green 30*30*1.3 2 Under Observation 16 Sep 2025

Bend Green 30*30*1.3 1 Under Observation 16 Sep 2025

Incline Bracing Rectification

Issue Details Severity Specification According to Manufacturer No. Of Elements Rectification Activity Closing Date

Combined Dent & Bend Amber 30*30*1.3 2 Replace 16 Oct 2024

Bend Amber 30*30*1.3 2 Replace 16 Oct 2024

Dent Green 30*30*1.3 2 Under Observation 16 Sep 2025

Upright Rectification

Issue Details Severity Specification According to No. Of Rectification Closing Date

Manufacturer Elements Activity

Loose Nut at U-B Connection Amber - 2 Repair As soon as

possible

Missing Bolt at U-B Amber - 3 Replace 16 Oct 2024

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 Issue Details Severity Specification According to No. Of Rectification Closing Date
Manufacturer Elements Activity

Connection

Dent Amber 110*80*2.2 1 Replace 16 Oct 2024

Paint Coating Defect Green 110*80*2.2 8 Repair 16 Sep 2025

Dent Green 110*80*2.2 5 Under Observation 16 Sep 2025

Bend Green 110*80*2.2 1 Under Observation 16 Sep 2025

Manufacturer - Doyle Asia

Baseplate Rectification

Issue Details Severity Specification According to Manufacturer No. Of Elements Rectification Activity Closing Date

Deformation Red 190*95*3.1 1 Replace 16 Oct 2024

Deformation Amber 190*95*3.1 4 Replace 16 Oct 2024

Tilted Anchor Bolt Amber - 2 Replace 16 Oct 2024

Deformation Green 190*95*3.1 2 Under Observation 16 Sep 2025

Loose Nut Green - 3 Repair 16 Sep 2025

Beam Rectification

Issue Details Severity Specification According to No. Of Rectification Activity Closing Date
Manufacturer Elements

Lack of Safety Locking Amber - 6 Other - Install the safety locking pin as As soon as
Pin soon as possible possible

Damaged Beam Green 100*45*1.5 4 Under Observation 16 Sep 2025

Connector Tabs

Dent Green 100*45*1.5 2 Under Observation 16 Sep 2025

Horizontal Bracing Rectification

Issue Details Severity Specification According to Manufacturer No. Of Elements Rectification Activity Closing Date

Bend Amber 25*20*1.5 1 Replace 16 Oct 2024

Incline Bracing Rectification

Issue Details Severity Specification According to Manufacturer No. Of Elements Rectification Activity Closing Date

Bend Amber 25*20*1.5 2 Replace 16 Oct 2024

Upright Rectification

Issue Details Severity Specification According to No. Of Rectification Closing Date

Manufacturer Elements Activity

Twisted Upright Red 85*65*1.9 4 Repair 18 Sep 2024

Dent Amber 85*65*1.9 12 Replace 16 Oct 2024

Missing Bolt at U-B Amber - 1 Replace 16 Oct 2024

Connection

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 Issue Details Severity Specification According to No. Of Rectification Closing Date
Manufacturer Elements Activity

Dent Green 85*65*1.9 20 Under Observation 16 Sep 2025

Paint Coating Defect Green 85*65*1.9 1 Repair 16 Sep 2025

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 Repair Strategy

Element No. of Rectification Activity

Manufacturer
Elements
Godrej Upright 2 Loose Nut at U-B Connection-Repair

Godrej Upright 8 Paint Coating Defect-Repaint

Godrej Beam 12 Paint Coating Defect-Repaint

Godrej Baseplate 1 Loose Nut-Repair

Godrej Toe Guard 67 Loose Fixing-Repair

Doyle Asia Upright 4 Twisted Upright-Repair

Doyle Asia Upright 1 Paint Coating Defect-Repaint

Doyle Asia Baseplate 3 Loose Nut-Repair

Doyle Asia Toe Guard 90 Loose Fixing-Repair

Inventory Summary for Replacement Activity

To execute the rectification activities, it is imperative to have or procure from the manufacturer the
necessary inventory of racking members. It is crucial to maintain an adequate stock of racking members
to prevent delays in the rectification process.

-
Manufacturer Element Specification Length/Ht of Member (mm) Replacement Item Units

Godrej Upright 110*80*2.2(mm) 9950 1

Godrej Upright-Baseplate Missing bolt - - 3

Godrej Beam 105*50*1.5(mm) 2700(Bay Width) 1

Godrej Bracing 30*30*1.3(mm) Horizontal Bracing 1

Godrej Bracing 30*30*1.3(mm) lnclined Bracing 4

Godrej Safety Locking Pin - - 1

Doyle Asia Upright 85*65*1.9(mm) 7600 12

Doyle Asia Upright-Baseplate Missing Bolt - - 1

Doyle Asia Bracing 25*20*1.5(mm) Horizontal Bracing 1

Doyle Asia Bracing 25*20*1.5(mm) Inclined Bracing 2

Doyle Asia Baseplate 190*95*3.1(mm) - 5

Doyle Asia Baseplate-Tilted Anchor Bolt - - 2

Doyle Asia Safety Locking Pin - 11
-

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COMPLIANCE AND STANDARDS
In adherence to stringent industry standards, our inspection and assessment of the racking system at are
conducted in accordance with the , a comprehensive guideline for ensuring the structural integrity, safety,
and operational efficiency of storage racks. The implementation of these standards is crucial to maintaining a
secure and compliant warehouse environment, aligning with industry best practices and regulations. The list
of standards used is given below.

EN15620 - Steel static storage systems — Adjustable pallet racking — Tolerances, deformations and
clearances.

EN 15629 - Steel static storage systems - Specification of storage equipment.

EN 15635- Steel static storage systems — The application and maintenance of storage equipment.

EN15512 -Steel static storage systems — Adjustable pallet racking systems — Principles for structural
design.

Compliance Overview

The following table provides a detailed breakdown of the clauses outlined in above mentioned standards,
their descriptions, and there compliance status as observed during the inspection.

Sr. Code Clause Description Compliance

No. Status

1 EN15620 6.3.3 Frame deflection in loaded condition should not exceed H/200. Compliant

2 EN15620 6.4.2 As per the code horizontal clearance in a bay for trucks for beam up Compliant
to height 9000 mm from ground should be at least 75 mm.

3 EN15620 5.3.2 Maximum vertical deflection of beam should notexceed L/200. Non-Compliant

4 EN15629 8.8.a Uprights at exposed ends of aisle and passageway used for Compliant
movement of truck should be protected by free standing upright
protectors.

5 EN15629 [Link] Movement joints under racks uprights should be avoided within the Compliant
rack area

6 EN15635 8.1.2 Instructions with regard to the safe load capacity shall be displayed Compliant
in a prominent location on or adjacent to the storage equipment so
that they are clearly visible, in the national language and in a
durable format.

7 EN15635 8.1.3 Truck drivers employed should be certificated/licensed Compliant

8 EN15635 8.3.3 The actual dimensions of the unit loads shall not adversely affect Compliant
the clearances provided for safe operation

9 EN15635 8.4.6 Aisles shall be kept free and goods shall be placed in the racking Compliant

Report Created In : iNODE RAMS | [Link]

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 Sr. Code Clause Description Compliance
No. Status

such that they do not form an obstacle.

10 EN15635 8.1.1 The user shall appoint a person responsible for storage equipment Non-Compliant
safety and the name of that person should be publicized to the
warehouse staff

11 EN15635 [Link] The PRSES shall ensure that inspections are made at weekly or Non-Compliant
other regular intervals based on a risk assessment. A formal written
record shall be maintained.

12 EN15635 [Link] A technically competent person shall carry out inspections at Compliant
intervals of not more than 12 months. A written report shall be
submitted to the PRSES with observations and proposals for any
action necessary

13 EN15512 8.8 In pallet racks, all of the beam end connectors shall be fitted with Non-Compliant
beam connector locks which prevent the connector from
disengaging when subjected to a vertical load

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CONCLUSION
Summary of Findings:
1. Visual Inspection
1.1 Beams:
• Damage
•25 issues (0 red, 1 amber, 24 green). The beams show minimal damage, with only 1 amber issue that
should be addressed, while green issues can be monitored for future concerns.

• Defects
• 19 issues (0 red, 7 amber, 12 green). While no critical defects were reported, the 7 amber issues (Lack of
safety locking pin) indicate areas that need attention to prevent deterioration.

1.2 Uprights:
• Damage
• 39 issues (0 red, 13 amber, 26 green). The upright components show moderate damage, particularly
with 13 amber issues(Dent) that require replace, while the green issues should be monitored.

• Defects
• 19 issues (4 red, 6 amber, 9 green). The 4 red defects (Twisted upright) are critical and should be
immediately addressed, followed by the 6 amber defects (Missing Bolt and Loose nut at U-B connection)
that indicate ongoing concerns.
1.3 Bracing:

• Damage
• 13 issues (0 red, 8 amber, 5 green). The bracing has no critical red issues, but 8 amber (Combined bend
and dent and Bend) issues indicate moderate wear that requires attention. Green issues should be
regularly checked.

• Defects
• No defects were reported for the bracing, indicating overall stability in this element.

1.4 Baseplates:

• Damage
• 9 issues (1 red, 4 amber, 4 green). The baseplates show 1 (Deformation) critical red issue that needs
immediate correction, while 4 amber (Deformation) issues should be addressed soon.

• Defects
• 6 issues (0 red, 2 amber, 4 green). The 2 amber (Tilted Anchor Bolt) defects are of moderate concern and
should be corrected to maintain structural integrity.

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2. Testing

2.1 Vertical Alignment And Beam Deflection Test Results:

• Vertical Alignment Test:
Out of 22 tests, none exceeded 100% misalignment

• Beam Deflection Test:

Out of 47 tests, only 1 test exceeded 100%, indicating critical beam deflection.

3.0 Structural Analysis Result

Utilization Ratio was checked for the model of Racks in Staad Pro, it was found that this ratio is
less than 1 for both OEMs (Doyle Asia & Godrej)

• Priorities and Tasks:

1. Beam Repairs
• Address the amber damage issue and amber defect issues to prevent future risks. Regularly
monitor green issues to ensure stability.

2. Upright Repairs
• Prioritize repairing the red defects and the amber damage issues to prevent structural failure. The
6 amber defects should also be corrected promptly.

3. Bracing Maintenance
• Repair the amber damage issues to maintain stability. Continue monitoring the green issues for
future risks.

4. Baseplate Correction
• Address the red damage issue and amber defects immediately to ensure the baseplates remain
secure and functional.
5. Safety Accessory Upgrades:

• Toe Guard
• The amber issues for loose fixing should be corrected immediately to enhance safety.

• Unit Stopper
• Unit stopper are found to be missing on site, we would recommend to install Unit Stoppers

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