Archive for the ‘racking safety’ Category

How to prevent a pallet racking collapse

The ramifications that come with a pallet racking collapse can be drastic. A collapse can cause costly damage to stock and other company property. It can also bring business to a standstill and could cause serious injuries or even fatalities. Here is how to prevent a pallet racking collapse.

The majority of incidents where pallet racking has collapsed have occurred as a result of bad practice, poor quality racking, or improperly maintained racking. Meaning these collapses could have been prevented.

In this article, we are going to explore some of the reasons why pallet racking collapses and the associated risks. We will also be giving you advice on some of the measures you can take to try and prevent a racking collapse from happening and causing significant damage or injury.

What are the risks of a pallet racking collapse?

A collapse poses a great number of risks that can be very costly to a business. Whether it be in time or money or reputation.

Loss of stock due to damage caused by a collapse is one of the most common associated risks. Not only can it be costly to replace the stock, but it can also cause a delay in manufacturing products or processing orders which will inevitably harm business.

A racking collapse can also cause injury to nearby workers or visitors, and these can be severe. The worst-case scenario is that a pallet racking collapse causes fatalities, and sadly this has been the case in some instances.

Businesses may also be subject to fines if they are found to have failed to keep working equipment in safe and working order, and they could even be prosecuted.

These are just some of the reasons why you must do everything you can to prevent a pallet racking collapse. Read on to find out some of the most common causes of racking collapses, and what can be done to prevent them.

What causes a racking collapse and how can it be prevented?

Cause: forklift truck collision

Forklift trucks are likely to be operated around pallet racking, and so there is a chance that a collision may occur. When racking is struck by a forklift truck, it may immediately collapse or cause damage that later results in collapse.

Preventative measure: generous aisle space

Utilising space as best as possible is a key objective in warehouses, but safety should be of the utmost importance. By leaving generous aisle space, forklift trucks will have more room to manoeuvre around and will be less likely to hit the racking.

You must always follow minimum aisle space guidelines provided by the forklift truck manufacturers to ensure adequate room is left for the forklifts to move around with ease.

Preventative measure: install rack protection

A cost-effective and simple way of protecting your racks is to install rack protection. The most vulnerable areas of racking systems are typically the end frames and corner columns.
You can strengthen these areas by adding bolted steel, floor-anchored, button-on, or poly snap-on rack protection.

Cause: overloading

Overloading is one of the most common causes of pallet collapses. If you put more on the racking than it is specified to withstand, this can have a negative impact on its structural integrity. It can cause the racking to become unstable and collapse.

Preventative measure: do not overload

You must follow the guidelines and weight restrictions of your particular racking set-up.

It is also important to note that a beams capacity is per pair not per beam. Their capacity also depends on the load being evenly distributed. This changes depending on whether you use decking or place pallets directly on the beams.

Cause: poor design

Racks should be tailor-made to cater to suit individual requirements. Their design should be dependent on the load’s size, weight, and density. If racking is not designed properly, bearing these factors in mind, this can be the cause of a collapse.

Preventative measure: seek professional advice

Ensure the racking system you have in place is fit for purpose, by enlisting a professional to come out and take a look at it. If you do not yet have racking, make sure that you use a reliable company to design and build your racking.

With 10 years of experience in engineering tailored storage solutions, you can trust Logical Storage Solutions to deliver a bespoke racking solution that is safe and meets your requirements. We have worked with some of the nation’s largest and most trusted brands, including IKEA, Amazon, DHL, and Tesco.

If you would like to find out more about our range of tailor-made storage solutions, please call 0845 689 1300 to discuss your requirements with a member of our expert team.

Common Pallet Racking Risks and How to Prevent Them

Pallet racking is a great storage solution for warehouses and is amazing for maximising the storage space available, making a warehouse run more efficiently. However, it is essential that all pallet racking is of high quality, installed correctly, and is inspected regularly as there are certain potential safety hazards that pallet racking can cause. Here we discuss four common pallet racking risks and how to prevent them from happening.

Damage from collision

There may come a time when the pallet racking system is accidentally hit with some machinery such as a forklift truck. If this were to happen it can not only potentially cause items to fall from the racking, it could also cause damage to the frame. Even if there doesn’t seem to be any visible damage after the collision, ensure that the issue is reported and the pallet racking inspected. The structural integrity of the racking may still be damaged. If you notice any significant damage, this must be repaired immediately before the situation gets worse.

All members of staff should be trained in the protocol for what to do when they spot racking damage. If the racking is left damaged it could lead to something much more severe and damaging, such as a collapse.

Also, consider installing additional measures to help lower the risk of the collision causing damage in the first place. End guards and rack bollards for example can be installed to help prevent the collision from happening or limit the impact if it did still collide. The design of the warehouse also needs to be taken into account when a collision occurs. Although it was inevitably an accident you need to consider whether the collision happened because the machinery didn’t have sufficient room to manoeuvre around the racking.

Products Overhanging

Overhanging products are a common pallet racking problem. Pallets should only be placed on the racking system designed for that specific pallet size. Overhanging items not only can cause strain, but products can also be damaged and may fall, causing injury to employees.

It is important when choosing pallet racking that you use specialists who can meet your exact needs. Doing this ensures the shelves are the correct height and depth meaning overhanging will never be an issue.

Overloading

Pallet racking systems have weight restrictions that need to be adhered to, to avoid injury to workers and damage to the racking system. All employees in charge of loading items onto the racking need to be aware of these weight limits. They also need to understand how to place the load evenly onto the racking to spread the weight. They should always check the current weight load as well as the maximum weight limit before new pallets are added.

Not installed correctly

Sometimes racking may not be installed correctly, which can pose a major danger. All pallet racking systems should be installed by professionals. Choosing specialists means they carry out safety checks before the racking is used. You need full reassurance that the racking is aligned correctly and is level before anything is placed on it. The manufacturers’ guidelines need to be followed exactly to ensure it is installed correctly and fit for purpose. If this does not happen, the racking can cause a major health and safety nightmare.

Pallet racking can help optimise warehouse operations and make daily tasks much easier. However, all the issues above must be considered to avoid damage or harm. By ensuring the pallet racking is installed and used correctly as well as inspected by a professional regularly, a warehouse manager can use pallet racking to help improve the efficiency and effectiveness of their warehouse operations.

The Importance of Pallet Racking Inspections

Even if you have just had new pallet racking installed in your warehouse, or you have had the same pallet racking for years, it is equally vital to have the equipment inspected. Here we discuss the importance of pallet racking inspections that all warehouse managers and businesses need to be aware of.

Just like any other equipment, even if the pallet racking is of the highest standard, you need to be realistic and know that over time you should expect general wear and tear. Even though pallet racking is extremely durable and robust, damage can still occur. Nuts and bolts can become loose which, if not detected early can lead to the foundations of the structure being unsteady. This could cause potentially dangerous problems in the future. Damage can also happen if the pallet racking has undertaken any physical hits from machinery such as forklifts accidentally hidden the racking.

Why do you need a pallet racking inspection?  

As part of the Health and Safety at Work Act of 1974, it is stated that “all adjustable pallet racking falls under the category of work equipment, which must be maintained and inspected on a regular basis”

The Provision & Use of Work Equipment Regulations (PUWER) of 1998 also states that all pallet racking shelving must meet the standards it sets out. This is in addition to the HSE guideline on Warehousing and Storage, HSG 76, states that “all racking systems should be of good mechanical construction, of sound material, adequate strength and installed and maintained in accordance with the manufacturer’s instructions.”

The inspections will observe the condition of the pallets, the positioning and types of loads stored on the pallet, the condition and type of floor the racking is fixed on plus much more. These are just some of the areas that are covered in the inspection. Once the inspection is done, a report will be issued with any recommendations or necessary actions.

By carrying out regular inspections, any issues can be dealt with head-on in a timely manner, reducing the risk of any accidents or further damage that could be costly to a business. By keeping the racking to the highest standards will also reduce the maintenance costs. It also helps towards creating a safer workplace and highlights to all warehouse employers that the business promotes health and safety in the workplace. This can considerably increase employees’ efficiency, happiness at work, and productivity if they know the equipment they are using is safe.

How often should the inspections take place? 

As a bare minimum, an expert inspection should take place annually. However, this is not the only inspection a warehouse needs to carry out. As stated in the EU Directive EN 15635, in addition to the annual expert inspection, internal inspections should also be undertaken on a weekly basis. Doing these regular inspections ensures that the racking remains fit for purpose and safe to use.

How do the inspections work? 

Warehouse inspections use a traffic light system in order to highlight any issues. These are called “damage categories”. Here is a description of the classifications:

Green Risk- The pallet racking system items that are damaged are within the limitations of BS EN 15635.

Amber Risk- The items are damaged beyond the limitations of BS EN15635. The rack should be offloaded as soon as possible within 4 weeks. The pallet racking system should not be used until the repair work has been completed.

Red Risk- Serious damage has occurred that are well beyond the limitations of BS EN 15635. If Red Risk occurs, the racking must be offloaded immediately and isolated from future use until the repair work has been carried out.

Who should do the inspections? 

A Person Responsible for Racking Safety (PRRS) should be nominated at every warehouse. Their responsibilities include carrying out the weekly internal inspections.

Although a technically competent person internally can review the pallet racking, it can often be beneficial to use an external company to undertake these inspections. They look at the warehouse environment and condition of the pallet racking with completely fresh eyes. They will provide you with impartial advice, will have a team of experienced inspectors that are used to inspecting a range of different warehouses and will give the warehouse’s PRRS a comprehensive report that highlights any damaged or missing components and/or structural imperfections. This level of detailed inspection and feedback can be invaluable to the management of a busy warehouse.

Unfortunately, there are many accidents that take place in warehouses, some of which are caused by the equipment they are using. Prevention is key. Even if you don’t believe there is anything wrong with pallet racking, having regular inspection reduces the risk of injury and can help the racking last longer as it is well maintained.

By understanding these potential risks and having pallet racking inspections on a regular basis can help minimise the damage caused, fix any problems quickly and therefore minimise the risk of any serious damage or industry to equipment or staff considerably, making it a safer workplace.

Here at Logical Storage, we can offer high-quality mezzanine flooring for your business and are ready to discuss your warehouse storage requirements. For more information visit our website or call us on 0845 689 1300.

Ultimate Safety Tips for Your Warehouse

How to Optimise Your Warehouse

Customer expectations continue to grow. An increase in online shopping makes people want access to a huge range of products quickly and easily. With many retailers offering next day delivery and free returns to match these high expectations, the need for warehouses to be optimised has never been greater. Here we discuss how to optimise a warehouse.

Are your products placed on racks correctly?

This may seem simple but it is surprising how many warehouses may not be placing their items correctly on the racking. The opening heights in your racks should get smaller or bigger depending on the load it is holding. As a rule of thumb, openings should be more than 6-inches taller than the load itself, allowing easy removal using a forklift.

Adjusting the rack height accordingly allows warehouse owners to completely customise the layout to specifically suit their products.

Consider the popularity of each SKU in your warehouse. An effective strategy can be to place slower-moving products in shorter rack locations. This can work well as the SKUs will not be picked as regularly, meaning that they do not need as much space.

Have you chosen the right racking system?

There are many racking systems to choose from and it’s important that you match the racking system to your individual business needs. You need to consider both the weight and size of your inventory and ensure the racking systems are optimised for this. The higher the number of beams in the racking system, the more weight it can carry. However, it also means there is less space between each one. It is, therefore, a balancing act to figure out the ideal racking system for your goods.

Are you optimising your space?

Warehouses have plenty of space. However, usually, this space is height and many warehouses do not make the most of this. A large proportion of your spare space will be higher up. Therefore, mezzanine flooring should be considered for those seeking more space to smooth their operations. They are great places to have additional storage or even office space, saving the floor level space for inventory only.

Are your aisles correct?

It can be tempting to narrow your aisles in order to fit more in, however, you need to consider this carefully. By doing so, you are limiting the space between the aisles. This can have a negative impact on efficiency if people struggle to manoeuvre through the aisles. Although you need to fit all your stock in the warehouse, you also need to ensure that the process is smooth and the warehouse remains a safe environment for all employees.

If you are struggling to make the most out of the space you have, then consider the points discussed above. Asking yourself these points may reduce the need to relocate or expand your warehouse by ensuring you are using all your current space to its greatest potential. Optimising your warehouse takes some planning, however, when done correctly you will end up with much more efficient operations which in turn can help you increase your revenue and output.

Pallet Racking Safety- Warehouse Safety Tips

Pallet racking is a great addition to any warehouse as they are a great storage solution and can improve efficiency and productivity. However, warehouse managers should be aware of measures regarding pallet racking safety. Issues can occur if the racking is damaged. These include collisions, incidents involving forklifts or overloaded pallets.

Here we discuss 7 ways you can improve the pallet racking safety in your warehouse

Always Use Suitable Forklifts

Forklifts should be suitable for the warehouse. Although the decision may be price-driven, a consideration should to the pallet contents should be given. Factors include the height and type of racking as well as aisle width. All of these factors will impact which forklift is suitable.

Handle With Care

Ensure all members of staff treat the pallet racking with care and use equipment in the correct manner. Place pallets evenly and squarely on the rack beams and remove damaged pallets from service.

Staff Training

Before anyone starts working with pallet racking in the warehouse, always ensure they have undertaken sufficient and detailed health and safety training which covers all aspects of how to correctly work with pallet racking.

Don’t Overload Pallets

Staff need to be aware of what the load capacity of the racking is and never exceed this. Overload pallet racking is asking for trouble and there is a reason why there are limits in place. Not only can it be dangerous for the employee, but it could also end up damaging equipment and products.

Keep Aisles Clear

Check for any obstructions in aisles as these can easily cause forklift collisions and other accidents.

Install Rack Protection

Invest in-rack protection to prevent damage from forklift collisions. Forklifts are heavy and can easily cause structural damage. To avoid any costs of damage or potential injuries, rack protection is a good option to help absorb the shock and impact of a potential collision.

Health and Safety Checks

Ensure safety information signs regarding the racking are visible and up to date. Implement clear processes for staff to follow in the event of an accident. Even though accidents cannot always be foreseen, an efficient accident process can help prevent any re-occurrences.

Carry out regular pallet racking inspections. Although damage may not be visible, the reassurance from a professional will provide peace of mind and will also keep your racking in the best condition for longer.

Ensuring your pallet racking remains in a safe condition is an ongoing task. Not only can damaged racking be harmful to employees, but it can also result in damaged inventories and associated costs. Implementing thorough safety measures can reduce this risk and therefore should be a priority for all warehouses that use pallet racking.

Here at Logical Storage, we can offer high-quality storage solutions, racking inspections and mezzanine flooring for your business. Call us on 0845 689 1300 for more information.

How to keep your workplace safe using racking

A lack of understanding of Health & Safety laws coupled with practical dangers such as heavy loads and overloading can produce plenty of risks to your business. Often however, the key to staying safe is as simple as choosing the right form of racking system and taking due care when choosing a supplier.

The dangers to businesses in the workplace
There are many dangers within a workplace. These can vary in businesses depending on what the environment is like. During 2017/18 a total of 144 workers were killed in fatal accidents and more than 650,000 non-fatal injuries were reported. This poses a huge risk to businesses as it can have bad consequences such as workers taking time off to recover or even in the worst case a worker being killed resulting in fines and even legal action.

How can racking help?
Racking is a great way to stop and prevent these dangers from occurring. This is because it is a highly-effective storage solution which enables for easy organisation and allows for heavy objects to be stored away safely. Saying this, racking will only be an effective solution if it is maintained properly, hence why it is incredibly important to have annual inspections.

Initial installation
Before even thinking about Health & Safety or maintenance for your racking, you need to ensure that you are selecting the right supplier and installer to get the job done. If your racking is faulty then it could have a negative impact on not only your productivity, but it can have a large impact on your Health & Safety standards.

Requirements on the racking
All manufacturers of warehouse racking are obliged to provide the safe loading data on the racking system, stating its maximum load and the maximum number of items that can be loaded at once.

This is to ensure that the users of the racking systems know how to load it properly so that it coincides with health and safety regulations. Failure meet these standards can have detrimental effects as it could cause racking and pallets to fall on the driver of a forklift or anyone stood underneath it.

Rules around the racking
In addition to the points mentioned above, your own housekeeping is essential to keeping your racking safe and in turn aiding the overall Health & Safety standards of your business. Keep workways clear for both forklifts and workers and have systems in place to collect and disperse rubbish as a minimum. Adopt a “see it – sort it” approach for maximum impact.

Inspections and maintenance
Inspections of your warehouse racking are a must as the HSE recommend having annual inspections by a SEMA approved racking inspector so that you are can highlight any problems and so you can stay up to date with any new legalisation.

This is where we can help. Here at Logical Storage we can offer high-quality racking inspections for your business and discuss your racking requirements. Click here for more details http://www.logicalstorage.co.uk/services/rack-inspection/ or call us on 0845 689 1300.

What causes racking damage?

Damage to the racking in your warehouse can have a devastating impact. Not only can it slow down your operations and cause damage to your stock, but it can also put your employees at serious risk of injury which in turn can spiral into financial loss and potentially damage to your reputation as a business. But how does racking damage occur in the first place? Here are a few common examples.

Vehicular damage
Warehouses are busy environments and while vehicles like forklifts are excellent tools in speeding up your operations and reaching areas that would be more challenging on foot, used incorrectly or without proper training they can pose serious hazards. Accidental collisions with racking systems are a common cause of breakages and while more serious incidents may be too hard to ignore, small bumps and knocks could go unnoticed but still do damage that compromises your systems.

Poor warehouse layout
While poor training of drivers can lead to collisions with racking, sometimes it is not the driver who is at fault. Instead cramped and poorly maintained areas that don’t utilize tools like coloured safety tape and notices or have poor housekeeping can result in drivers having to make tight maneuvers that can often end in collisions.

Overloading
The most common cause of racking failure is that of overloading. By calculating factors like frame size, beam size and depth we can work out exactly what the limit should be for weight on your racking. However, if advice is ignored and your racking becomes overloaded then structural damage is bound to occur at some point. It is important to make it clear to workers through both training and notices exactly what weight limits are.

Seek advice
The key to avoiding racking damage is to quickly identify faulty or damaged racking. By organising periodic reviews of your racking with a professional company you can quickly identify small signs of wear and tear before they develop into something much worse.

Logical Storage is highly skilled in spotting the often hard-to-find signs of racking degradation. We carry out regular reviews for a number of businesses helping them to keep their systems in good working order and to maintain their legal obligations under the Health & Safety Act.  To find out more please call us on 0845 689 1300.

Why you need to take racking damage seriously

Whether you are a large business operating in an industrial sized building, or a small operation with just a few employees, racking inspection and repair is absolutely essential to your business.

Damage to racking through poor placement of stock, damage by forklifts or other equipment can risk the integrity of your racking and put both your product and your employees at risk.

Time and time again, unsafe racking has resulted in catastrophic failures where racking has collapsed, hitting other structures and resulting in widespread damage to both systems and stock. This then results in equipment, storage systems and stock having to be replaced which means hours of wasted time and heavy costs incurred. Can your business afford the downtime?

Equally, there have also been plenty of cases of unsafe racking resulting in damage not just to stock but also employees who have been caught in the crossfire of a collapse. Should an employee be injured you could be liable under the Corporate Manslaughter and Homicide Act (2007).  An incident of this sort would not only be terrible for those involved but could also leave your business with a loss of reputation and having to divert your attention to lengthy, expensive legal issues.

The key question here is how can this be prevented? The number one way that you can prevent a racking collapse is to have regular inspections of your racking by a trained professional looking out for bent or damaged beams, loose attachments, overloading, corrosion, misalignments and more. Damage to racking can be difficult to spot unless you know what you are looking for which is why it is important to seek out experienced help.

Logical Storage is highly skilled in spotting the often hard-to-find signs of racking degradation. We carry out regular reviews for a number of businesses helping them to keep their systems in good working order and to maintain their legal obligations under the Health & Safety Act.  To find out more please call us on 0845 689 1300.

Racking and Health and Safety – what you need to know!

The Health and Safety Executive offer important guidance when it comes to keeping your employees safe. A failure to follow guidelines has historically seen business owners face large fines and legal damages when their actions, or inactions, have led to employees being injured.

Health and Safety guidelines should cover every aspect of your operations and racking is no exception. The most relevant advice for businesses utilizing racking is often the HSG76 Warehousing and storage: a guide to health and safety. This offers key information for managers and supervisors around health and safety in warehouses and storage facilities to help reduce injuries and improve occupational ill health targets set by the government.

One of the key points raised in the guidelines is the importance of having regular racking inspections carried out by trained experts. Racking needs to be properly maintained once it is installed and used properly. This means that it should never be overloaded or climbed upon (as is stressed in HSG76) and it is important to also guard it from damage by vehicles such as fork-lift trucks that use your warehouse.

Even the smallest amount of damage can have a big impact on your racking safety. Small fractures of hairline cracks can significantly impact the integrity of your racking and could lead to one or more of your employees being struck by falling objects or trapped under a collapsed structure.

With proper maintenance, racking is one of the most formidable types of storage that you can have and can make a huge impact on the productivity of your business. However, if handled badly and not regularly reviewed it can also slow down your operations and the day to day running of your business.

Logical Storage is highly skilled in spotting the often hard-to-find signs of racking degradation. We carry out regular reviews for a number of businesses, helping them to keep their systems in good working order and to maintain their legal obligations under the Health & Safety Act.  To find out more please call us on 0845 689 1300.