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Nimonik Expert EHS Series: Rack Safety and Compliance

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Nimonik knows that pallet racks, although crucial to the logistics of you operations, are often overlooked at your facilities. A collapsing rack can not only kill staff, it can damage inventory, cause delays and reduce profitability, hence the importance of properly inspecting and maintaining your racks frequently.

In this presentation, Rack Net-Works’ Principle Engineer and Lead Rack Inspector, Tony Mulholland and Brian Rusciolelli, cover a range of elements pertaining to the inspection of racks.

This webinar covers various types of racking, the standards ensuring rack safety, the process of inspection and how to ensure that racks are not overloaded.

Publicado en: Ingeniería
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Nimonik Expert EHS Series: Rack Safety and Compliance

  1. 1. Rack Safety & Compliance Tony Mulholland & Brian Rusciolelli
  2. 2. Kim Chanel Vallée-Séguin Communications Manager, Nimonik Brian Rusciolelli Lead Rack Inspector, Rack-Net-Works Tony Mulholland P.Eng. Principle Engineer, Rack-Net-Works
  3. 3. • Terminology and introduction to storage racking • Briefly introduce the various types of racking and their vulnerabilities • Understand the Standards and how often racks need to be inspected (frequency) • Describing the process of inspection and how to respond • Capacity and ensuring racks are not overloaded Rack Safety & Compliance Agenda
  4. 4. Rack Safety & Compliance: Components of Racking Row Spacer Beam Bracket Beam Section Post Protector Diagonal Brace Horizontal Brace Post/Column Post/Column
  5. 5. Rack Safety & Compliance: Components of Racking Baseplate/Shims Post Protector Diagonal Brace Horizontal Brace Post/upright/ column Anchor
  6. 6. • Most common type of pallet rack • Rack is arranged in a single or a series of rows such that every pallet loaded on the rack faces an aisle • Common damage: front post in the lower 5’ • Collapse: rare, except for single rows (10 times as likely than a connected row) Rack Safety & Compliance: Vulnerabilities of Selective Rack
  7. 7. • Tunnel use for passage of lift truck to place pallets on rails • Rails run the length of the tunnel on both sides and support pallets on their edge • Damage: rear frames and lower 8’ of all uprights • Collapse: prone, especially if no transverse bracing Rack Safety & Compliance Vulnerabilities of Drive In Racks
  8. 8. • Similar to selective rack except beam levels support a system of tracks and carts that allow the pallets to be moved to the rear. • Damage: typically lower front post – carts can get hung up if not maintained • Collapse: rare Rack Safety & Compliance Vulnerabilities of Push Back Racks
  9. 9. • Rack usually consists of column with perpendicular arms used to support long items • Damage: arms by dropping loads • Collapse: rare, unless constructed in- house Rack Safety & Compliance Vulnerabilities of Drive In Racks
  10. 10. • ANSI MH16.1 – Racking Manufacturers Institute (RMI) • European EN15635 – European Committee for Standardization • CSA – A344 Canadian Standards Association • prime reference in Canada • Meets or exceed most of the requirements of RMI & EN • Today we will refer to A344 – 2016 even though it is not formally approved yet Rack Safety & Compliance Regulations & Requirements
  11. 11. • CSA A344 – clause 8.1.9 calls for routine inspections (typically monthly) as well as ‘expert inspections’. • “Expert inspections are typically done under the supervision of a professional engineer, with the engineer taking responsibility for the damage inspection process and reporting. CSA A344 - clause 8.1.5 addresses frequency inspections. The expert establishes the frequency of inspections based on a risk analysis. Rack Safety & Compliance Regulations & Requirements
  12. 12. • Damage comes in many forms and each situation can be unique – not easy to evaluate severity • We use a method based on the CSA and European Rack Standard – and call it the RAG method (Red Amber Green) • When doing expert inspections we also use engineering judgment to set the limit of structural imperfection Rack Safety & Compliance Inspection Methods – RAG
  13. 13. • Damaged is measured over 500mm or 20” (not 1000mm as in the EN standard) • Items in the chart are not all in the EN guideline and can vary from site to site • Example of recognizing structural vulnerability is : • 4 mm on diagonal brace of single row is more conservative than 5 mm on connected row Rack Safety & Compliance Damage Severity
  14. 14. • CSA A344 requires the expert to establish the damage limits for a particular site or structure • Additional parameters can come into play that are specific to site, such as out of plumb, twisted posts, beam damage, etc. • The charts below illustrate how these limits can be established for a site Rack Safety & Compliance Damage Severity
  15. 15. • Each damage requires a response, using the RAG Method this chart illustratesappropriate responses: • Classifyingand Tagging items as Red Amber Green sets up Immediate Action • Immediate Action – unloading/locking out of service, avoid loading if possible, monitor for further damage • Corrective Action is a secondary decision that deals with the repair or other remedial action Rack Safety & Compliance Responding to Damages FIND ITEM CLASSIFY & TAG RED AMBER GREEN UNLOAD AVOID LOADING IF POSSIBLE REVISE PRACTICES OR TRAIN ONLY REQUIRES FUTURE MONITORING HAZARD RESOLVED REPAIR OR REPLACE FIND | CLASSIFY | DETERMINE IMMEDIATE ACTION | SPECIFY CORRECTIVE ACTION | CLOSE OUT
  16. 16. • RAG Method requires inspection items be treated with a multi-stage RESPONSE: • Categorize & Tag items as Red Amber Green thereby setting up Immediate Action • Immediate Action – specify immediately put out of service, corrective action required, may require corrective action – monitor • Corrective Action - a secondary decision that deals with remediation and prevention Rack Safety & Compliance Responding to Damages FIND ITEM CATAGORIZE & TAG RED AMBER GREEN immediate danger immediately put out of service seek guidance as per clause remediation required may remain in service corrective action is required REVISE PRACTICES OR TRAIN minor deficiencies may require repair, column protection, and/or modified operating practice & monitor to ensure the condition does not worsen CLOSE OUT HAZARD RESOLVED REPAIR OR REPLACE FIND CLASSIFY IMPLEMENT IMMEDIATE ACTION SPECIFY CORRECTIVE ACTION CLOSE OUT bad operating practice instruct the operators
  17. 17. • We recommend severity be represented by numbers 1 to 9 as it allows what is in effects “shades” of each color 1-3 GREEN 4-6 AMBER 7-9 RED • The numbers are essentially a RISK index - a relationship between probability and consequence Rack Safety & Compliance Assessing Damages high 4-­6 7-­8 9 9 moderate 4-­6 4-­6 7-­8 9 low 2-­3 4-­6 4-­6 7-­8 minimal 1 2-­3 4-­6 4-­6 minor significant critical catastrophic Probability  or  Likelihood Consequence
  18. 18. • CSA A344, clause 8.2 - The engineer supervising the expert inspections should establish time guidelines for corrective action • The chart below is how severity can be assessed a response time Rack Safety & Compliance Assessing Damages
  19. 19. Total Unloading Partial or Center-to-center off loading Rack Safety & Compliance Unloading Types • CSA and EN both require unloading if RED • EN standard has special requirements on AMBER – do not reload • There are two types of unloading (total and partial)
  20. 20. • CSA A344.1 clause 8.2.2 calls for method to clearly identify rack that is unsafe by “marking or tagging” • Below is one way to tag out a level or bay Rack Safety & Compliance Marking Damaged Racks
  21. 21. Rack Safety & Compliance Case Study – Training and Monitoring • Racks  inspected,  plus employees   were  trained  on  Rack  Awareness  and   Inspection • Damage  immediately  was  reduced  -­ inspections  continued • Damage  began  to  increase • Additional  training  was  provided  and   again  damage  incidents  decreased • Big  gains  -­ Increase  in  safety,  and   decrease  in  maintenance • Inspection  and  training  is  a  cost  saver   206 85 34 87 102 29 0 50 100 150 200 250 2010 2011 2012 2013 2014 2015 number of recorded deficiencies
  22. 22. • CSA clause 7.3 - the weight of loads placed in the racks must not exceed the load capacity of the rack structure Rack Safety & Compliance Capacity Signage • Clause - Load plaque need to include a reference to documents that establish the maximum permissible loading • The method used should be selected based on the nature of the facility, and achieved by: • use of warehouse management software (WMS) • load plaques & awareness of the weight of the pallets • trained operators using approved storage procedures • insuring the capacity of the rack can support the heaviest pallet in the facility
  23. 23. PLANNING  YOUR  NEXT  STEPS 1. Arrange to have an inspection done by an expert third party 2. Ensure the capacity of racks is formally established by an engineer & review documents to ensure they are up to date 3. Set up a program to have staff conduct monthly inspections and ensure they are trained to do so 4. Make arrangements for having the damaged racks repaired or replaced. If repaired, ensure repairs are formally approved 5. Implement the recommendations of the Expert inspection (frequency of inspection, documentation, response time, damage limits)
  24. 24. For more information 1-888-608-7511