Reference

Reducing or eliminating the possibility of damage to pallet racking is one of the most important aspects of warehouse safety. There are a number of complimentary approaches you should adopt to minimise damage.
 

Racking inspection requirements.
Regular inspection of racking is essential. The inspection should follow a hierarchical approach using 3 levels of inspection as follows:-

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1. Damage inspection by warehouse operatives

2. Weekly inspections as a visual check from ground level

3. Regular inspection at least once a year by a ‘technically competent' person

 

The Person responsible for racking safety (PRRS).
HSG 76 identifies the need to appoint a ‘competent person’ be responsible for racking safety known as a PRRS (Person Responsible for Racking Safety). The PRRS will then be responsible for coordinating the various aspects of rack safety i.e.  ensuring that the racking is used, inspected and maintained in accordance with the appropriate regulations and guidelines.

 

Operator training.
This is unquestionably the most important factor in eliminating damage in the warehouse.  You, the user, must ensure that the warehouse staff are trained in the appropriate use and just as importantly limitations of the storage equipment. It is the responsibility of the user to maintain the racking in a safe condition. Drivers of materials handling equipment should receiver regular training.  We recommend a familiarisation programme for all new drivers.  This firstly allows you to acquaint the driver with the controls and features of your particular truck since as with cars the modern trucks now have many ‘whistles and bells’ and your new driver is unlikely to be familiar with all of them.  It also allows you to alert then to site specific conditions such areas with restricted headroom, one way systems, safety zones etc.  In addition it also allows you to assess their capabilities – not all drivers are equal and a lot of damage can be caused while the new driver acquaints themselves with your storage racks!  Many companies now put new drivers on ‘limited duties’ for a couple of weeks so they can be observed, or buddy them up with an experienced member of staff.  Both methods have shown clear benefits in reducing damage.

 

Racking maintenance.
Any damaged component noted in the inspection as requiring repair or replacement should be taken out of use in accordance with the damage code as dictated by the SEMA guidelines and repaired or replaced by suitably trained personnel as required.

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Rack protection.
End frame protection is recommended for all end frames between a gangway and an aisle and also for all end frames between a drive through tunnel and an aisle in truck operated racking.  Elsewhere you should conduct a risk assessment and act accordingly. also do beware of retrofitting rack protection which inevitably reduce operating clearances and may as a result lead to an increase in damage.

 

Where freestanding protection is fitted it should allow adequate clearance off the frame component.  Fitted too close and it will restrict or prevent inspection of the concealed component, and also can lead to ‘knifing’ damage when the guard flexes under impact as some lighter duty guards are designed to do.  SEMA guidelines recommend a minimum clearance of 25mm with 40-50mm being preferred. And don't skimp on the fixings and always use good heavy duty fixings otherwise you will be forever replacing them!

 

There are an increasing number of ‘clip on’ type guards that affix directly to the rack upright.  There are a number of different types and designs and features but do beware that whilst offering the benefits of speed of fitting and their high visibility profile they also have significant drawbacks. 

• They require regular removal to allow for your weekly and annual inspections.

• They can lull drivers into a sense of false security by believing regular impacts with the racks are not a problem.

• They can conceal damage that would have otherwise been immediately apparent.

• They are not really suitable for exposed corners of storage racks where freestanding guards are the only suitable option.

 

 

HSG76 & Racking protection.

 

HSG 76 has a number of initiatives to minimise damage including the following sections on rack protection:

Clause 639 states: Where racking is likely to be struck by lift trucks and other vehicles, it should be protected. Generally, such damage is at the lower levels of the racking – use renewable column guards to minimise the risk of damage from accidental impact. Corner uprights in a run of racking are especially at risk and should be suitably provided with a protective device in a conspicuous colour.

 

Retrofitting upright protection devices to an existing aisle where they have never been provided can have the effect of reducing the available clearances for fork-lift truck manoeuvres, which can in some circumstances increase the amount of damage caused. Such situations need consideration on a case-by-case basis.

 

Unfortunately, clause 639 is being interpreted by many, especially some suppliers, as meaning that all racking uprights are likely to be hit and should therefore be protected by rack protectors and even that it’s the Law in the UK. This is not the correct interpretation of this clause.

 

Drivers must be reminded that guards and protection on racking are not to be used as positioning guides or back stops. Drivers must always leave clearance between pallet and guard.

 

Rack protection should be regarded as a ‘last resort’ means of avoiding rack damage and other methods of damage prevention should be considered before taking the decision to use rack protectors.

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The protection of storage racks is not just dependant on physical protection, but also relies on a number of items including:

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• The specification

• The design of the system

• The installation

• The defined responsibilities of the person responsible for racking safety

• The training of the operatives

• The inspection procedure

• The maintenance procedure

 

Items to be considered should include:

 

• The type of damage to be protected against

• Whether other methods of protection are more appropriate

• The type of protector required

• Whether the protector will reduce clearances, potentially leading to more damage

• Whether the protector may hide potentially serious damage

• Whether the protector may lead to less reporting of damage

• Whether the protector may result in operatives using the protector as a buffer

 

 

Where physical protection is considered it is vital to ensure that is is effective and appropriate and not just a sticking plaster approach that may lead to other problems further down the line.