Beware ta of ck ha? I-- ? ,ls

eccentricity of column loading. Each manufacturer designates a style of beam-to-column connection, either tabbed, slotted, bolted or clipped with locking clips.

Solution: Each beam-to-column connection should be checked to make sure it is consistent with the manufacturer's connection style and installation instructions.

Inadequate Clearances

THE HUGE storage racking sys-

I tems of home centers and lumberyards may hide some serious threats to person and property. A selfinspection program can prevent potential accidents through an organized system of checking for danger signs. The Rack Manufacturers Institute has identified l1 of the most common rack hazards and corrections that can be made to eliminate them.

I I. Misalignment of Racks

Racks can be misaligned by being out of plumb vertically or horizontally, or not corrected for the slope of floors. Sometimes various size racks are improperly butted up against one another with protrusions in the aisle. Racks improperly connected together can cause whole groups of misalignments.

Misalignment is particularly a predominant hazard in drive-in struc- tures. Often the front frame is anchored out of alignment in one bay and spreading support rails in the adjacent bay, which could contribute to pallet fall-through. Fork truck and stacker interference caused by rack misalignment can also lead to permanent deformation of the rack.

Solution: Most misalignment hazards can be safely eliminated by adherence to the manufacturer's installation drawings and specifications. Check all connections to make sure they are on the proper levels; all plumbing should be done on the vertical plane to make sure that the rack is properly aligned from front to back. Shimming and plumbing should be done on the horizontal plane to make sure the rack is level.

(. Improper Beam Installation

Improper beam installation can adversely affect shelf capacities and

Inadequate clearances involve improper openings for handling equipment and inadequate load-toload dimensions at various levels. Improper and unsafe clearances are caused by placing loads too close together or on top of each other, making material more easily dislodged.

Solution: Set up the rack for proper clearance as outlined by the manufacturer. Make sure that when a pallet is lifted out from a set of beams or from a bay level there is ample room to clear the front and back beams.

4. I-p.op"r Aisle Width

Changes in the size of loads or type of forklift used or protrusions into the aisle may result in undersized aisles. Inadequate clearance may prevent operators from turning into a bay opening or pulling a load out of an opening.

Solution: Refer to the original drawings of the manufacturer's designs and the original layouts of the racks at installation and verify the consistency of the pallet load to the beam spacing to the aisle width. Determine what size aisle best accommodates the particular material handling equipment and ensure adequate load-to-load dimensions. If necessary, change the rack positioning for new material handling equipment.

I D. Dislodgment of Accessories

Many rack installations have accessories (front-to-rear supports, straight decks, grid decks, ledges, cradles) that can be dislodged by material handling equipment.

Solution: Have a professional maintenance program that requires checking fasteners and verifying that all loose accessories, cradles and materials are indeed fastened as prescribed by the manufacturer.

0. spittrg" of Goods

If unstable loads are stored, items may fall behind racks, into adjacent sections or protrude into the aisle. Bulk material that hangs over a pallet can be easily dislodged when the pallet is raised. The spillage can harm the materials as well as the rack system.

Solution: In bulk storage racks, take care to ensure loads are intact and bound by plastic wrap or secured in bins or by ledging materials. Make periodic inspections to ensure there are no loose packages that will be dislodged when the load is removed from the rack. Spilled material should be picked up immediately.

7. obstructions

Often when there is not enough room in the rack for the material to be stored, aisles become filled with pallets, threatening the safe operation of the racking system. Floor obstructions and litter in aisles and around the rack are also serious hazards.

Solution: Prohibit pallets on the floor and institute a 'Janitorial" program around the racks on a fixed schedule.

8. Deficient Handling Equipment

The condition of forklifts, sideloaders and hand trucks and the way they are operated can directly affect the safety of rack structures. Equipment deficiencies include poorly maintained equipment (e.g., bad wheels or hydraulic units, defective or misaligned forks and inexperienced operators.

Solution: Have fixed programs for equipment maintenance, inspection and operator training.

0. Damaged Racks

Most rack damage is due to continuous battering over the years by trucks and handling equipment. The battering can accumulate in magnitude, gradually reducing the overall structural capacity of the rack and possibly resulting in rack failure.

Solution: To minimize collision damage, use aisle guards. A guard can either be a device that is secured to a column to strengthen it or a sacrificial type of structure that protects the column, particularly at important traffic areas.

Damaged racks should be replaced. As soon as a column becomes twisted or distorted, the rack should be unloaded and the section removed and

Story at a Glance

11 potential perils in storage racks ... steps to detect Problems and prevent disaster.

replaced with a new upright section.

10. n"t""iorated Racks

Some racks are set up outdoors, near heat treating are.rs, or where acid and salt corrosion is in the atmosphere. They may deteriorate and rust, reducing rack capacities.

Solution: Inspection and maintenance are the solution. Vulnerable systems should be bolted with plated bolts. When rust appears, racks should be wire-brushed and coated with a corrosion-resistant coating, such as an epoxy or suitable corrosion protection material. If there is any indication that the connections are impaired, corroded racks should be removed.

ll. s".- Sprearling

Spreading results from shocking or overloading a set of beams, causing deformation at the connection, pulling away from the upright column, and possible collapse.

Solution: A routine inspection program is needed. To verify this condition, remove all damaged beams, replace them with proper beams and realign the rack using manufacturer' s instructions.

Maintaining Your Racks For Safety

[.I^pecting Racks

Inspection programs vary in accordance with the size and intended use of each fack installa.: tion. Make timely visual inspecti on s t:o:::ensure tlte:r::inte grity',,of racks. Encourage and expect peisonnel to report any rack damage as soon as it occurs.

B. Correcting Damage

Since 907o of

Rack Damage

occurs between the floor and first horizontal beam, most damage can be seen from floor level. Check with,'the rack manufactufe; for advice on the proper means to correct damage. In most cases, dimpled, buckled or severely bent rack iomponents should be replaced. Moderate damage, such *s dbnting or slightly skewing upright columns, can be corrected bY adding bracing or splices or simply heating the member and returning it to vertical.

G. Prerenting Rust

Rack use dictates the importance of rust prevention or touch-up painting, Any high moisture or cooler applicationi calls for car-eful attention to paint conditions. All coftponents ftom,,floor to,,,ceiling should be checked, though lcsi frequently than damage checks.

0. rignrcrriog Lags

RaCks and connecting bolts should be tightened in accordance with manufactur€r-supplied torque data, since the security of the entire s;lstem depends on proper fastening. Conduct random checks to ensure there has been no loosening.

E. Housekeeping

Cleanliness and proper lighting are keys to a well-run operation. Proper lighting facilitates rack enty and pallet placement and aids in reducing rack damage.

- RackManufacturers Institute