As a warehouse manager or operator, ensuring the safety and reliability of your racking system is of utmost importance. Regular visual inspections are vital for identifying and addressing any damage or weaknesses in the pallet racks. However, with knowledge of the specific terms for each rack component, it can be easier to communicate effectively and take action to rectify issues.
In this blog, we will delve into the main components of a racking system and provide quick tips on what to look for during inspections. By familiarizing yourself with these terms, you’ll be better equipped to address any damage promptly, reduce the risk of accidents, and ensure your warehouse meets regulatory compliance. Explore the essential components of maintaining a safe and efficient warehouse environment.
The upright frame consists of columns, i.e., the two vertical components where the braces are welded. During inspections, examining the front and rear columns is crucial. For instance, twisted columns can significantly diminish the rack’s load capacity, representing the maximum weight it can safely bear.
Neglecting such damages could result in a collapse of the racking system, underscoring the importance of promptly addressing significant column damage to ensure its safety.
Figure 1: Damaged Upright.
Pay attention to the following issues during your inspection:
Tip: At both extremities of a rack system, your upright column should always exceed the height of the highest beam. It prevents packages from falling onto a pedestrian pathway, especially in high seismic zones.
Braces are diagonal or horizontal members bolted or welded between frame columns in a specific pattern, creating an upright structure. Their purpose is to counter cross-aisle forces exerted on the rack’s frames and enhance the overall stability of the racking system.
Check all the horizontal and diagonal braces:
Beams serve as the horizontal structural elements in a pallet racking system. Their primary role is to bear the weight of stored loads, typically pallets, and transfer this weight to the columns to which they are securely connected. While rack beams can support heavy loads, their capacity is not unlimited.
Figure 2: Beam Deflection.
When assessing beam and pallet positioning, the following issues should be looked at:
It’s crucial to ensure that the pallets are in proper condition. What factors should be considered when it comes to damaged pallets? Numerous things could go wrong, such as cracks, glass, odor, contamination, outdated labels, protruding nails, and overloading. If a fully loaded pallet is damaged, it’s difficult to determine whether it broke during the loading process or was already broken. Nonetheless, all staff members should ensure that the pallets they work with are in good condition.
Baseplates, or footplates, are welded to the bottom of a racking column or repair unit to distribute the weight of the racking system on the ground. Additionally, they facilitate secure anchoring of the system using anchor bolts.
Anchors, or anchor bolts, ensure the pallet rack system remains securely positioned by fastening it to the building floor. Despite their small size, pallet rack anchors for column bases are critical.
Per industry standards, at least one anchor per baseplate must anchor the racking system to the floor. This configuration enhances the racking system’s ability to withstand forces such as earthquakes, wind, overturning, shear forces, or accidental impacts on the lower ends of the columns.
Figure 3: Damaged Baseplate.
When you walk the facility and evaluate the anchoring system, the following issues should be reviewed:
Safety bars are supported by pallet racks’ front and rear beams, designed to support misplaced pallets temporarily. Although not mandatory, they are highly recommended to prevent pallets from falling between beams. These bars can help prevent accidents that could cause severe employee injuries and damage to goods or storage systems.
Be sure to focus on the following aspects during your inspection:
Relying solely on standard pallet rack components may not be enough. Consider additional rack safety components to bolster your rack safety measures. Let’s explore some essential rack safety add-ons that can elevate your safety standards and contribute to a safer work environment.
Safety pins, also known as connection locking devices, locking clips, or bolts, are small yet crucial devices designed to prevent beams from dislodging in pallet racks. Their primary purpose is to secure the pallet rack beams to the uprights, ensuring they stay connected even when exposed to upward forces caused by pallet loads or forklift impacts.
As per RMI’s ANSI MH16.1-2012, safety pins are commonly included as a standard component by the racking system’s manufacturer and recommended as a safety practice. Safety pins are installed at the connection point between the beam and the column. Since each beam is supported on both ends, it’s essential to have two pins installed per beam to ensure maximum stability and safety in the pallet rack system.
Wire mesh decking is installed on pallet rack shelves. It serves as an extension of safety bars, providing a reliable solution to prevent pallets, products, and debris from slipping through the gaps between beams.
Load-carrying members are designed to stabilize two rows of upright frames, ensuring the rack system functions at its intended load capacity. These components serve as spacers for back-to-back pallet racks, maintaining consistent spacing between the racks. They should be positioned at elevations that create a direct load path between the columns of the back-to-back frames.
During your inspection, make sure to review the following issues:
Do your rack inspections cover all aspects and remain current? Below are additional factors to consider concerning the safety of your warehouse racks:
In summary, rack inspections can sometimes be challenging, especially for those needing more time, resources, or expertise. That’s why teaming up with a rack safety expert is so beneficial. By partnering with these professionals, you can focus on your business while they take care of rack safety. Whether you need advice on safety practices, help with maintenance, or support in an incident, these experts are here to ensure your warehouse runs safely and efficiently.