RACKMART RAC-270-MAN-001 Selective Pallet Racking User Manual

RACKMART RAC-270-MAN-001 Selective Pallet Racking User Manual

Terminology

• Competent person: Person who has acquired through training, qualification or experience the knowledge and skills to carry out the task effectively and safely
  Note 1 to entry: For pallet racking structures a competent person may include the OEM, engineer, designer, supplier or rack inspector.

• Pallet racking: Pallet racking is a material handling storage aid system, designed specifically to store materials on pallets (or “skids”) and accessed by mechanical handling equipment.

• Unit load: individual stored item that can be placed or retrieved in one operation.

• Unit load depth clearance: minimum horizontal distance between adjacent unit loads in the cross-aisle direction of a double entry (double-sided) racking situation.

• Unit load height clearance: minimum vertical distance between the highest point of the unit load and the underside of the pallet beam immediately above.

• Upright: vertical members that comprise the upright frame and are subject to predominantly compressive forces parallel to their longitudinal axes and have provision for systematic attachment of pallet beams.

• Upright frame: vertical frame assembly composed of uprights and bracings to support design loads transmitted through pallet beams and operating equipment.

• Upright protector: component in front of an upright frame that is secured either to the floor or an upright, or both, and designed to resist minor impact loads.

Introduction

This manual provides advice and instructions to users of Selective Racking systems supplied and installed by Rackmart Pty Ltd.

With the combination of moving materials handling equipment (forklifts and stock pickers), heavy loads and high storage levels, a warehouse can be a dangerous work environment without safe work practices. It is essential that all personnel are adequately trained in the correct use of MHE that operate within rack structures, they understand the risks involved, and comply with the safe operating procedures required to ensure those risks are minimized.

Purpose

This manual provides advice and instructions to users, maintenance personnel and WHS officers to ensure the safe and efficient use of the equipment.

Racking systems are made up of steel components which, if incorrectly installed, damaged or overloaded, can lead to significant hazards for users and the surrounding environment. It is essential that the points in this guide are understood and acted upon if serious accidents are to be avoided. Even minor damage can add to the overall weakening of a rack structure that could lead to a collapse.

This manual should be understood by all personnel involved with racking systems and is designed to be used for training purposes.

Applicable standards

All equipment has been designed and tested in accordance with the following standards:

Principles
EN 15629| Steel Static Storage Systems. Specification of Storage Equipment
SEMA| Code of Practice for the Design of Adjustable Pallet Racking
ANSI MH16.1-2012| Specification for the Design, Testing and Utilization of Industrial Steel Storage Racks

Selective Pallet Racking Component

Selective Racking consists of various components that work together to deliver a safe storage structure for palletised goods. The two main components are upright frames and beams, all components can be seen in (Fig. 1).

Beams.
Beams are the load bearing horizontal portions of the system that attach to the upright posts via connectors. Beams are produced from a uniquely shaped ‘box beam’ design to ensure strength and rigidity.

Upright Posts.
Upright Posts are the vertical perforated sections of a frame and are connected by braces at regular intervals. Upright posts are roll formed as a single continuous length for maximum strength and durability.

Bracing.
Bracing consists of diagonal and horizontal braces that connect the two upright posts together forming an upright frame. Bracing helps transfer the loads down to the ground.

Footplates/Baseplates.
Footplates or baseplates are bolted to the bottom of each upright post and then fixed to the concrete slab via special masonry anchors. They secure the racking in place and provide stability.

Upright Frames.
Upright Frames consist of upright posts, bracing and footplates. Upright Frames are usually designed and manufactured by APC Storage Technology. APC upright frames are punched with APC’s unique hole configuration and are supplied galvanized for maximum visibility and corrosion resistance.

Selective Pallet Racking Basics

t is important that the user understands as much as possible about the equipment. This not only concerns the racking system, but also the quality and type of product and mechanical equipment used to load and off-load the racking.

Loading

The total weight (including weight of pallet), overall dimensions (including any overhang), security and stability of all units loaded to the pallet racking must be considered prior to loading, ensuring that the designed load is not exceeded.

Material Handling Equipment

Make sure you use the correct material handling equipment, considering the type, capacity, maximum lift height and minimum practical operating aisle.

Modifications to the Racking Configuration

Each racking design is based on the beam loading capacity and the distance between beam levels. If either of these factors need to be changed, it is essential that a competent person is contacted so the structural integrity of the design can be checked

According to the AS 4084.2: 2023, Modifications may be required if any of the following occurs:

• Change of type or make of MHE.
• Change in the method of handling unit loads or pallet type.
• Change in the type of goods handled.
• Change in the weight or size of unit loads.
• Introduction of overhanging loads or load make up accessories.
• Change in the throughput of the storage system.
• Change to racking specifications.

Load Signs

Safe Working Load (SWL) signs (Fig. 2) contain critical information on the load capacities relevant to the row of racking the operator is about to enter. This information must be read and understood by all MHE operators working within the rack system. It is recommended that MHE operators check that unit weights being placed into the rack correspond to the unit weights specified on the SWL sign attached to the end upright frame(s) at the entrance point of the rack that should be positioned where it is visible to operators 2m above floor level.

• A – Unit Weight
• B – Uniformly Distributed Load (UDL) (A x units per level)
• C – Total Bay Load (B x number of raised levels)
• D – Height to First Beam Level
• E – Subsequent Beam Levels
• F – Frame Tolerance grade

Operation and maintenance signs

The specific wording is now a requirement of the new standard to ensure end users are aware of their responsibilities to instruct operators on how to operate safely around the racking, report any damage, carry out regular inspections and whom to contact if there are any doubts or concerns.

The signs for operation and maintenance are typically combined with the load signs, necessitating their visibility to operators at a height of 2 meters above the ground level as well. (Fig. 2.1).

Pallets

The quality, design and material of a pallet is a critical factor in the design of pallet racking systems. Some pallets, in particular the plastic variety, may not have sufficient strength in the base structure to be used in pallet racking, without the use of additional steel supports. Please check with your pallet supplier to ensure that the pallets in use are capable of being used on Selective Pallet Racking.

Use of the wrong type of pallet, or damaged pallets can lead to an unsafe load. Selective pallet racking is designed for specific pallet types and cater for Australian Standard Pallets. Refer to your installation drawing for pallet dimensions

• Pallets should be designed for the racking and lock into position.
• All pallets should have front to rear bearers capable of supporting the loaded pallet – other styles of pallets require additional support (refer customer to manufacturer).
• Broken pallets should be removed from the racking.

It is important to advise your racking supplier during the rack design which pallets are being used and only those specified should be used in the racking.

• Australian Standard Pallet: 1165 x 1165mm (Nominal)
• European Pallet: 800 x 1200mm
• Industrial Pallet: 1000 x 1200mm
• NZ Pallet: 1200 x 1000mm

For more information on pallets refer to AS 4068:1993 – [Flat Pallets for Material Handling].

Loading & Unloading

Impact from Material handling Equipment (forklifts) or the unit loads they carry are the leading cause of rack damage. To minimize the chance of impact damage it is important that operators follow these guidelines.

Safe use of pallet racking by forklift operators.

The forklift must have the adequate capacity and be capable of lifting loads to the required height. Also ensure the aisle clearance is suitable for the forklift to operate correctly and clear of any obstructions. All operators of mechanical equipment interfacing with pallet racking must be trained and licensed in accordance local and national requirements.

Regular safety audits should be carried out by a competent person. All operators should become familiar with the layout of the storage facility, the design loads for each bay of racking, and the recommended clearances required between unit loads and the rack structure.

DO

• Read SWL signs and understand unit load limitations
• Report any accidental impact from MHE or unit loads
• Identify and report beams without safety clips.
• Identify and report any potential hazards.
• Identify and report any damage to rack components.
• Identify and report any areas that receive repeated impact or damage.
• Maintain good housekeeping by keeping aisles clear of rubbish and clutter.
• Ensure minimum clearances between unit loads and rack structure.

DO NOT

• L ift unit loads too high when loading or unloading them.
• Overload beams beyond their rated load capacity.
• Make contact with any portion of the rack structure other than the top surface of the beam with the pallet when loading or unloading.
• Do not ‘shunt’ pallets by driving the pallet further into the rack with the forklift once the pallet has been lowered onto the beams.
• Place damaged or broken pallets into the rack.
• Modify the rack structure in any way without written approval from the rack manufacturer.

Use the correct tine length

The correct forklift tine length (Fig. 3.1) is critical to ensure load stability and minimize rack damage. Forklift tines must be of sufficient length to support all loads (Fig. 3.2). Forklift tines must not extend beyond the load (Fig. 3.3).

Picking up pallets

When lifting a load into place on the racking system, it is important that all goods are positioned square to the materials handling equipment (Fig. 3.4). If the palletized goods are not positioned square on (Fig. 3.5) then the effective size of the load is increased, resulting in reduced control of the load and damage to the racking system or product when positioned within the rack.

Entering the rack

To safely deposit or retrieve a load, the forklift MUST approach the racking square on, not at an angle (Fig. 3.6).

• DO NOT attempt to deposit or retrieve a load if the forklift is not aligned (Fig. 3.7).
  

• DO NOT ‘nudge’ a pallet to position it correctly on the beams.

• DO NOT slide pallets on the rail.

• DO NOT ‘shunt’ the pallets on the beam (beam damage comes from this practice).

Positioning the pallets

Incorrect pallet load placement can be dangerous to workers and can damage racking or goods.
Below are key points to note when positioning pallets into the racking:

• Loads should be evenly distributed across the beam length
• Load weight should not exceed the designed load capacity
• Loads should be positioned evenly across the pallet to ensure even weight distribution, unless the rack structure has been specifically designed for uneven load distribution (Fig. 3.8).
  

Note: Under no circumstances should the operator use the mechanical handling equipment (MHE) to push a pallet into position once it is on the beams (shunting). This practice can exceed design loads for horizontal forces and can permanently damage the racking structure.

Unit Load Clearances

AS 4084.2:2023, clearly outlined the guidelines for minimum vertical clearances between the top of the unit load and the beam level above. ( Fig. 3.9).

If the equipment operator is at ground level:

• For unit loads below 6 meters in height, the minimum vertical clearance should be 100 mm.
• For unit loads equal to or above 6 meters in height, the minimum vertical clearance should be 125 mm.

If the equipment operator is elevated to the storage level or other visible devices are used to help the operator clearly see the unit load and adjacent rack during loading and unloading, the minimum vertical clearance above 6 meters can be reduced to 100 mm.

There shall be a minimum horizontal clearance of 75 mm between the unit load and upright frame; and 100 mm between adjacent unit loads on a common beam pair.

Load packing

Ensure the load is packed correctly on the pallet (Fig. 3.10).

DO NOT load a pallet with an overhanging load unless the rack has been specifically designed for this (Fig. 3.11) and minimum clearances can be met.

Rack Protection

It is recommended that Rack Protection be used on all entries. Rockmart, through its business partner APC Storage Technology, can supply a range of racking protection that reduces impact damage. It is important to note that although these products are used to protect racking, they can also be damaged and may require replacement or repair to properly function. Below is a list of rack protection that can be used on Selective Pallet Racking.

APC Bodyguard®
The Bodyguard is formed from a rubber composite (EPDM). Its patented design deflects impact away from the upright whilst also absorbing any direct impact force, diffusing it through the guard.

Angle Guard
Easily attachable directly to the post, this unit is designed to deflect any frontal impact without causing any loading obstructions to users.

Column Guard
A ‘U’ shaped guard designed to be secured to the floor at the base of the post via heavy duty concrete anchors. This unit protects the front and sides of the racking, absorbing any impact directly into the ground.

Corner Guard
For use at the end of a racking run, this unit protects the corner of the racking post in high traffic areas while minimizing intrusion into the aisle space.

CIR Guard
A circular unit designed to ‘wrap around’ and deflect impact damage away from upright posts without causing an obstruction in the aisle. The unit is secured via a base plate connection as well as a top plate connection.

End Frame Barrier
Racking protection designed to protect the exposed ends of pallet racking runs in high traffic areas. This is done by absorbing or deflecting impact from forklifts and unit loads entering the aisles. Curved corners wrap around the frame to protect the posts from any side impact.

Damage Reporting

If any signs of damage are noticed, report them to your supervisor immediately. A damaged rack
should not be used or accessed until it is inspected by a competent person. It is important for
operators to understand the risks and cleared for use.

The below is responsibility of the user:

• The ongoing safety of the storage equipment.
• Inspections, reports and repairs relating to racking shall be documented and retained by the end user until the racking is removed from service.
• Carry out informal inspections at a frequency based on:
  a) The result of a risk assessment (e.g. daily or weekly)
  b) At intervals recommended by a competent person.

Impacts

Report ANY and ALL impacts and assess any signs of damage.

Note: An increasing number of front beams are being damaged from impact caused by MHE operators ‘shunting’ the pallet further into the rack once it has been lowered onto the beam. This is a poor practice designed to keep pallets square on to the aisle and keep as much distance as possible between adjacent pallets across the aisle width. It is important for operators to understand the risks associated with this practice as it is difficult to determine the degree of impact.

Damage to Racking

Any damage to a racking post will reduce its load carrying capacity. When damaged, the post may fail under its normal working load.

Safety Notes

• Recognize that racking components are produced from light gauge thin walled sections which can only tolerate limited impact.
• A single failure in a pallet racking structure can lead to a catastrophic failure or collapse which may result in injury or even a fatality.
• Racking, MHE and load interactions are critical to operating a safe workplace.
• Keep aisles clear at all times.
•  A small dent / deflection in a post could render the racking unsafe and may require replacement.
• Even though racking beams are adjustable, the beam level position is critical in the design of the total structure’s load-bearing capacity. Levels must not be removed and/or repositioned without consulting the manufacturer or competent person.
• Beam safety clips are to be fixed at all times.
• Damage inspections should be carried out in accordance with AS4084-2023.
• Racks shall be inspected every 12 months as a minimum.
• AS4084-2023 introduces a process to inspect racking for corrosion and provides guidelines and schematic examples for evaluating the degree and classification of corrosion damage. If there is any doubt about the level of corrosion during an informal inspection carried out by an end user, advice should be sought from a competent person.
• Users should be encouraged to report any damage.
• Employers have a duty of care under the WHS Act to provide and maintain plant and systems that are safe and without risk to health. Having regular inspections will assist employers to comply with their obligations under the WHS Act.

Rack Inspections

It is recommended to conduct systematic evaluations of pallet racking systems at regular intervals, informally during daily or weekly site safety checks and formally at least once every 12 months, as a minimum.

Rockmart, through its business partner APC Storage Technology, offers a full inspection service to assess your racking. Contact our office on (08) 9478 5755 or visit our website to find out what we can offer.

Disclaimer

Whilst every care has been taken in the preparation of this information, Rackmart Pty Ltd and its agents accept no responsibility for the accuracy of the information supplied. The company expressly disclaims all and any liability to any person whether a purchaser of any product, or otherwise in respect to anything done or omitted, by any such person in reliance, whether in whole or any part of this publication.

Office Location

Perth
232 Collier Road,
Bywater,
Western Australia, 6053
P: (08) 9478 5755
F : (08) 9277 1198
sales@rackmart.com.au

References

• Shelving, Storage Racks & Office Equipment - New & Second-hand | Rackmart

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