Capita plc, commonly known as Capita, is an international business process outsourcing and professional services company with a focus on Telecoms, Media & Technology; Retail & Consumer Products; Energy & Utilities; Government & Transport and Financial Services.
The Challenge
A warehouse relocation was required for 14,000 pallet locations. The warehouse was required to be in the North-East of England and with easy motorway access. The relocation had to be planned to not disrupt operations and require additional internal human resources.
The Solution
Capita first engaged with Rack Group several years ago requesting racking repair and inspections. Rack Group have since become a preferred racking partner for Capita. Rack Group designers and installation engineers supported Capita in sourcing new warehouse premises.
Six properties were reviewed around the North East of England which were in close proximity and had easy access to motorways. For some of the identified properties, racking designs were produced by Rack Group, to understand how the space could be optimized for to assess the immediate and longer term warehouse storage capacity.
A warehouse property was finally sourced which Rack Group estimated could support 15,000 pallet locations. The relocation was planned in four phases over a 10 week period to minimize disruption to operations. Standard adjustable racking was sourced from AR Racking and installed by the Rack Group. The stored items in the original warehouse were transported after each phase of installation, on time and on budget.
To maintain the integrity of the racking from vehicle impact damage, barriers were also installed. These consisted of end of aisle barriers supplied by RMI and Rack Armour® to protect the racking uprights.
The Benefits
Zero disruption to operations and no loss of output was achieved through the phased installation and relocation of assets.
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The project was delivered on time and on budget including the sourcing, installation and protection of the racking.
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Warehouse sourcing was expedited and storage space optimised, with the assistance of Rack Group designers and engineering team..
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Single point of contact to source racking, installation and inspections, plus impact barriers due to Rack Group being part of IWS Group, a family of industrial solution providers.
"With a major relocation in a very tight timeframe, Rack Group worked with us every step of the way, from layout design, planning, phasing and installation. Our need to move meant that we had started to decant our old premises to the new location, even before the racking installations began. Rack group came in and got on with the installations, to allow us to place items onto the racking almost as soon as each phase was completed. I would have no hesitation in recommending Rack Group for any size of project."
Mary Collins Head of Projects, Group Property Capita PLC.
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Every inch of space counts, so maximising the use of your warehouse’s square footage can lead to increased efficiency, productivity, and profitability. But what if you’re running out of space and considering moving to a new warehouse? Moving can be costly and disruptive to your business, but there’s a solution that can save you money and the hassle of relocating: installing a mezzanine. Mezzanines are raised platforms that provide additional floor space in your warehouse, allowing you to create new storage space, repurpose existing space, or add new workspaces.
In this article, we’ll explore the positives and negatives of mezzanine installations, and how implementing a mezzanine can help you save on the cost of moving to another warehouse while maximising your current space.
Positives of Installing a Mezzanine Floor
Increased Storage Space: A mezzanine floor can provide additional storage space in your warehouse, allowing you to make the most of your vertical space. This can increase your storage capacity without taking up valuable floor space.
Creation of New Workspaces: Mezzanine floors can create new workspaces, such as offices or break rooms, by adding an additional level to your warehouse. This can free up valuable floor space and improve organization and accessibility.
Cost Savings: Installing a mezzanine floor can save the cost of moving to a larger warehouse or expanding your current one. By using the available vertical space, you can increase your storage capacity without incurring the cost of a new building or additional land.
Time and operational savings: By simply removing the need to expand or relocate to new premises will not only save time for many colleagues but maintain maximum operational efficiency.
Increased Property Value: A mezzanine installation can increase the value of your property by adding additional square footage to your warehouse, making it a more desirable asset in the long run.
Negatives of Installing a Mezzanine Floor
Upfront Costs: Mezzanine floors can be expensive to install, and the cost will depend on the type of mezzanine, the size of your warehouse, and other factors. Additionally, ongoing maintenance costs may also be required. Factoring all these costs into your ROI is paramount and start by gaining a number of quotes from installers. The design is also important and the designer should be able to provide a number of cost-related options.
Building Codes and Permits: Installing a mezzanine floor typically requires obtaining building permits and meeting building codes. This can add additional costs and time to the installation process. A good installation company should be able to help you with all of these items, from documents to installation in line with regulations and standards.
Disruption to Workflow: The installation process of a mezzanine floor can cause disruptions to your warehouse’s workflow, leading to downtime and decreased productivity. Ensure your installation company provides a plan to mitigate disruption including a phased plan and out-of-hours work schedule.
Is a Mezzanine Floor the Best Solution for Your Warehouse?
What will the mezzanine be used for? Will it be used for storage, production, or office space? Understanding the purpose and use of the mezzanine will help determine the size, weight capacity, and other requirements for the installation.
Available Space
How much available space do you have in your warehouse? The size and layout of your warehouse will determine the size and design of the mezzanine. Consider the height of your ceilings, the placement of existing equipment and structures, and any other space limitations.
Future Growth
Consider if your business is likely to expand in the future. If so, a mezzanine floor can provide the flexibility to adapt to future growth without incurring the costs of moving to a larger warehouse.
Building Codes and Regulations
What are the building codes and regulations in your area? It’s important to ensure that the mezzanine installation meets all safety and regulatory requirements. Make sure to work with a reputable mezzanine installation company that is knowledgeable about local building codes and regulations.
Load Capacity
How much weight will the mezzanine need to support? The load capacity of the mezzanine will depend on its purpose and use. For example, a mezzanine used for heavy equipment storage will need to have a higher load capacity than a mezzanine used for office space.
Accessibility
How will the mezzanine be accessed? Consider the location of stairs, elevators, and other access points to ensure that the mezzanine is easily accessible for employees and equipment.
To ensure that you select the right mezzanine for your warehouse, it’s important to work with an experienced and knowledgeable mezzanine installation company. Visit our website to learn more about our mezzanine installation services and schedule a consultation with our experts.
Does Your Business Need a Mezzanine
In conclusion, adding a mezzanine to your warehouse can provide a range of benefits for your business, including optimising space, creating new storage and work areas, increasing efficiency, and enhancing safety. By choosing the right mezzanine design and working with a professional installation company, you can maximise the use of your warehouse space and improve your operations.
If you’re considering adding a mezzanine to your warehouse, make sure to do your research and choose a reputable and experienced installation company. Schedule a consultation with their experts to determine the best mezzanine design for your business needs and to ensure that the installation is done safely and correctly.
To learn more about our mezzanine installation services and schedule a consultation with our experts. Don’t miss out on the opportunity to optimise your warehouse space and improve your operations.
If you run a business that utilises a warehouse as its operational hub, you understand the importance of efficiently utilising the available space.
Whether it’s maximising storage capacity or creating new work areas, there are numerous strategies to optimise the square footage of your warehouse. An effective solution worth considering is the installation of a mezzanine floor—a raised platform that offers additional floor space within your warehouse. This blog post will delve into the various types of mezzanines that exist and provide guidance on selecting the most suitable one for your business.
Benefits of Mezzanine Flooring
Mezzanine installations offer numerous benefits for warehouses of all sizes and industries. Here are some of the key advantages of adding a mezzanine to your warehouse:
Increased Storage Capacity and Flexibility
One of the most significant benefits of mezzanine installations is the extra storage space they provide. Mezzanines can be used to store products, equipment, and supplies, allowing you to make the most of your vertical space. This increased storage capacity also gives you more flexibility in organizing your warehouse, enabling you to optimise your workflow and increase productivity.
Improved Organisation and Accessibility
Mezzanines can help you organize your warehouse more efficiently. By using the extra space to store products and equipment, you can create more accessible pathways and workspaces, reducing the time it takes to locate and retrieve items. This improved organization can help you improve your workflow and productivity, reducing errors and increasing accuracy.
Creation of New Workspace and Repurposing of Existing Space
Mezzanine installations can also create a new workspace and allow you to repurpose existing space. If your warehouse is running out of floor space, a mezzanine installation can provide an additional level for offices, break rooms, or other workspace. Additionally, a mezzanine can help you repurpose existing space by allowing you to move storage or equipment to the upper level, freeing up floor space for other purposes.
Increased Property Value
Finally, mezzanine installations can increase the value of your property. By adding a mezzanine, you’re essentially creating additional square footage, which can increase the overall value of your warehouse. If you’re looking to sell or lease your property in the future, a mezzanine installation can help you attract more buyers or tenants and increase your return on investment.
Types of Mezzanine Installations
When it comes to selecting a mezzanine installation for your warehouse, there are numerous options to choose from. Here are just some of the most common types of mezzanine installations:
Free-Standing Mezzanines are self-supporting structures that don’t require any additional support from the building’s existing structure. These mezzanines can be easily relocated or expanded and are ideal for warehouses with high ceilings.
Rack-Supported Mezzanines use existing pallet racking as the support structure for the mezzanine platform. This option is ideal for warehouses with limited floor space or those looking to add storage space above their existing pallet racking.
Shelving-supported mezzanines use existing shelving units as the support structure for the mezzanine platform. This option is ideal for warehouses with limited floor space or those looking to add storage space above their existing shelving units.
Structural steel mezzanines are designed to support heavy loads and are ideal for warehouses that need to store large or heavy equipment or machinery. These mezzanines can be custom designed to fit your specific needs and can be used for storage, production, or office space.
Installation and Maintenance
Once you’ve decided you need a mezzanine for your warehouse, it’s important to ensure that it’s installed and maintained properly. Here are some key things to consider:
Design and installation It’s important to work with a professional mezzanine design and installation company that will consult and advise on the optimum solution for your workplace. This will include not only the best design but is in the best location, good access and a cost-effective solution. A company will also ensure that your mezzanine meets all regulatory requirements and building codes.
Regular Maintenance It is essential to ensure that your mezzanine stays in good condition and continues to operate safely. Make sure to schedule regular inspections and maintenance with your mezzanine installation company.
Safety Features Make sure that your mezzanine installation includes all necessary safety features, such as guardrails, handrails, and safety gates. These features will help prevent accidents and injuries in your warehouse.
Employee Training Make sure that all employees who will be working on or around the mezzanine receive proper training on how to use it safely. This includes training on how to access the mezzanine, how to load and unload materials, and how to use any safety features.
If you’re considering installing a mezzanine in your warehouse, make sure to work with a reputable and experienced mezzanine installation company that can provide not only professional installation and maintenance services but also guidance on safety, regulations and compliance.
A racking inspection is crucial to maintain a safe and efficient workspace, but it is something that can be easily overlooked. Without regular inspections, warehouse racking can pose serious safety hazards, leading to injury and inventory damage. That’s why inspection consultations are crucial for any business that uses warehouse racking.
The Rack Group has written this piece to discuss what makes an effective racking inspection, why it matters, regulations, and how it can benefit your business. So, whether you’re looking to undertake your own inspections or want to understand how to choose a third-party inspection service, keep reading for our expert insights.
Understanding SEMA and why it matters for warehouse inspections
For warehouse racking inspections one organisation stands out as a recognized authority on safety and quality: the Storage Equipment Manufacturers’ Association, or SEMA.
SEMA is a UK-based trade organisation that represents manufacturers and suppliers of storage equipment, including racking and shelving systems.
So why does SEMA matter when it comes to inspections? For one, SEMA-approved inspectors have access to the latest industry knowledge and adhere to strict safety standards, ensuring that their inspections are thorough, accurate, and effective. In the eyes of HSE it makes them the ‘Technically Competent” person who might be a trained specialist within an organisation, a specialist from a racking supplier, or an independent qualified rack inspector.
If you’re looking for an effective racking inspection, we highly recommend choosing a SEMA-approved inspector, to have confidence in the safety and quality of your warehouse racking.
The importance of HSE guidelines for warehouse inspections
Another crucial factor when choosing a racking inspector is adherence to HSE (Health and Safety Executive) guidelines for warehouse safety and inspections. HSE is the UK government agency responsible for promoting and enforcing workplace safety, including warehouse operations.
Following HSE guidelines for racking inspections can have numerous benefits for businesses. For one, it helps businesses maintain compliance with government regulations, avoiding potential fines and penalties as well as injury and fatalities.
Following HSE guidelines helps with record-keeping and documentation, which can be crucial in the event of an accident or liability claim.
When choosing a racking inspector, it’s important to ensure that they are accredited and follow HSE guidelines for safety and inspections. Familiarising yourself with these guidelines can also help you identify potential safety hazards and ensure that your warehouse is as safe as possible.
What to expect from a racking inspection and inspector
Inspections are designed to help prolong the lifespan of your racking systems by identifying any signs of wear and tear or damage that could compromise safety or performance. Addressing these issues early, it can help you avoid costly repairs or replacements down the line.
In addition to the cost savings associated with identifying potential risks early, inspections can also help you reduce liability and claims. By ensuring that your racking systems are safe and compliant with the latest health and safety legislation, you can protect your business from costly claims and legal fees.
An inspection process begins with a visual inspection of your storage systems, during which the inspector will look for any signs of damage, wear, and tear if it meets with the original manufactures design and build standards, or other issues that could compromise safety. They will also check that your systems are in compliance with the latest health and safety legislation, including HSE regulations.
Once completed the inspector should provide you with a detailed report outlining any issues identified and recommendations for how to address them using the SEMA/PUWER/EN15635 Red, Amber, and Green classifications. Sometimes this report can be overwhelming or confusing, which is why a good inspector will take the time to walk you through any identified situations in the report. The inspector should want to ensure that you have all the information you need to make informed decisions about how to address any issues and ensure the safety and compliance of your storage systems.
According to SEMA, after an annual racking inspection, a warehouse racking inspector should provide the following:
Detailed report: The inspector should provide a detailed report outlining the findings of the inspection. The report should include a description of any damage or defects found in the racking system, as well as recommendations for repairs or replacements.
Risk assessment: The inspector should provide a risk assessment that evaluates the safety of the racking system. The risk assessment should identify any potential hazards or risks associated with the racking system and recommend measures to mitigate those risks.
SEMA’s RAG classifications are used to assess the severity of damage or defects found during a racking inspection. Here’s a breakdown of the classifications and their corresponding Priority rated actions:
RED RISK – Areas where a high level of damage is identified of over twice the SEMA limits. This warrants immediate offloading and isolation of the affected area until repair work is carried out
AMBER RISK – Areas where the damage identified is greater than the SEMA limits. This warrants remedial work to be carried out. However, the damage is not sufficiently severe to warrant the immediate offloading of the area. No additional loads shall be placed in the affected area and, once the pallet positions in this area are emptied, they should not be refilled until the repairs are carried out. If repairs are not carried out within 4 weeks, an Amber risk item automatically becomes a Red risk item
GREEN RISK – Areas where damage is present, however, the level of damage is within the SEMA limits and should be recorded for further consideration at the next inspection
By using the RAG classifications and corresponding Priority rated actions, it aims to help you and racking inspectors prioritize and address any safety issues identified during an annual racking inspection. This ensures that any urgent risks are addressed immediately and that less urgent issues are addressed in a timely manner, reducing the risk of accidents and maintaining a safe working environment.
A good inspection company should go beyond just the inspection process and identifying issues, to provide support throughout the inspection process and beyond. Any inspector’s goal is to help you create a safer and more efficient warehouse environment that can help you reduce or eliminate repetitive damage, claims, and liability.
How to choose a racking inspection provider
Now that we’ve discussed the importance of racking inspections and what makes an effective inspector, how do you go about choosing a racking inspection provider? Here are some key factors to consider:
Experience: Look for an inspector or provider with a proven track record of conducting effective and thorough inspections. Ask about their experience working with businesses similar to yours and ask for references if necessary.
Qualifications: In addition to experience, look for a provider with relevant qualifications and certifications. For example, inspectors who are members of SEMA (Storage Equipment Manufacturers’ Association) are held to high standards of safety and quality.
Reputation: Do some research on potential providers to see what their reputation is like in the industry. Look for reviews and testimonials from previous clients and ask for references if necessary.
Cost: Of course, cost is an important factor to consider as well. However, don’t make cost your only consideration when choosing a provider. Remember that investing in a quality inspection can save you money in the long run by reducing the risk of accidents and associated costs.
When choosing a racking inspection provider, it’s important to take the time to research potential options carefully. Don’t be afraid to ask questions and seek out references to ensure that you’re making an informed decision based on your needs and budget. By choosing a qualified and safety-conscious provider, you can protect your employees, inventory, and bottom line.
When should I have racking inspected?
The frequency of pallet racking inspections required depends on a variety of factors that are particular to your site but, typically, the first inspection should be carried out within 6 months of the installation becoming operational and at least annually from then on.
PUWER is a set of regulations that apply to work equipment, including racking systems used in warehouses. The regulations require that all work equipment, including racking systems, has not deteriorated through use.
Under PUWER, warehouse racking systems must be inspected at regular intervals to ensure they remain safe for use. The frequency of inspections will depend on a number of factors, including the type of racking system, number of pallet movements, age of the system, previous damage recorded, type of system even new FLT operators and the level of risk associated with the racking system.
Finding an inspection partner with industry experience and commitment to cost savings!
At Rack Group, our inspectors don’t just identify issues but work with our clients to help address and stop issues from reoccurring.
We’re proud to draw on our 40 years of experience in the racking industry and to provide top-quality inspection services that help our clients save money and reduce risk. We’ve seen it all when it comes to racking systems, and our experience enables us to identify potential risks and issues before they become costly problems.
Our experienced qualified inspectors will walk you around any identified situations in the report, to spend the time to assist you with the information you need to ensure your storage systems are safe and compliant with the latest health and safety legislation. A large part of what we do is guidance on how and why issues occur, the action required to rectify them, and more importantly the actions needed to stop them from reoccurring. This further helps reduce risk and prolong the lifespan of your racking…ultimately saving you money!
On completion of our electronic inspection from our PUWER and SEMA accredited team you will have a clear and concise digital next day report, highlighting;
Priority-rated actions to SEMA’s Red, Amber, and Green classifications
Recommendations that will prolong the life of your storage equipment
Guidance to improve workforce safety such as housekeeping
Our services go that extra mile to provide a comprehensive, friendly, and tailored service which has seen us become the pallet racking inspection company of choice, for many recognisable names within the UK and Ireland.
Our commitment to cost savings and risk reduction is just one of the many reasons why businesses trust us to provide top-quality inspection services. If you’re interested in learning more about how we can help you save money and reduce risk, please don’t hesitate to contact us to schedule an inspection. The Rack Group looks forward to working with you.
If you have any questions about our services or products, please contact The Rack Group over the phone at +44 (0)1226 784488 or email via info@therackgroup.com.
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PALLET SAFETY GATES
FEATURES: Safely load and unload pallets from mezzanine floors. Multiple options to suit requirements.
IDEAL FOR: Mezzanine floors, new installations or retro-fitting to existing structures.
FEATURES: Compact, high-density storage. Optimum use of space with semi-automated FIFO (First In, First Out) or LIFO (Last In, First Out) options.
IDEAL FOR: Warehouses with high turnover of stock, high volumes of pallets, seasonal merchandise, cold and freezer storage, perishable and non-perishable stock.
All racking is required to have a Safe Working Load Sign
Key things to know:
The safe working load limit of the rack needs to be displayed clearly for colleagues to see
The signs should be mechanically fitted in a conspicuous location 2m from the floor
They should be made from corrosion-resistant material
Every sign should include: the suppliers name, safe working loads, height to first beam, and beam pitch
REPAIR: Replace damaged Weight Load Signs or order replacement signs if your storage system has been altered since installation. Need help calculating your safe weight load? We can help.
PREVENT: Ensure all aisles of racking have Weight Load Signs to avoid beams becoming overloaded and unsafe.
Bracing and frames can be hit by moving pallets or MHE.
Key things to know:
Bracing can become torn or bent, compromising the load capacity of the racking
Damage can reduce the capacity of the frames to withstand accidental frontal impact
Deflections should be no more than 10mm in either direction before needing repair
Deflections under 10mm should still be monitored and reassessed at the next inspection
REPAIR: Replace or repair damaged bracing as soon as is required of the SEMA code of practice.
PREVENT: Although sometimes unavoidable, protecting racking frames with impact protection barriers can help reduce how close MHE can get to the racking. Training operators on careful and accurate placement of pallets can also help prevent damage.
Missing bolts and locking pins can result in dislodged components
Key things to know:
FEM recommends all racks are fixed to the floor with at least 1 bolt per base plate
Beam safety locks, or locking pins, provide resistance against accidental beam dislodgement
There should be 2 safety locks per beam
Dislodged beams result in unstable pallet loads and an increased risk of falling from height
Each racking type has a compatible locking pin, do not use nuts and bolts to secure beams to uprights
REPAIR: Order replacement bolts and safety locks. Replace any damaged beams that have become dislodged and require repair.
PREVENT: Regular inspections should include checking for any missing bolts / locks, as well as any dislodgement of beams. Hold stock of safety locks to replace any missing components.
Base plates are essential components for the safety of racking
Key things to know:
All racking should be fixed to the floor using 1 or more bolts per base plate
Unsecured racking is more vulnerable to collapse from impact
Damage to base plates can often cause damage to the floor
REPAIR: Damaged base plates should be repaired or replaced as soon as they pose a safety risk.
PREVENT: Ensure all base plates are secured to an unbroken floor with at least 1 bolt. Protect MHE from hitting uprights and base plates with racking protection guards.
Racking front and rear uprights are often impacted by MHE.
Key things to know:
Bends or twists can compromise the load capacity of the whole racking system
Deflections forwards or backwards should be no more than 3mm before needing repair
Deflections sideways should be no more than 5mm before needing repair
Repairing uprights by welding replacement sections compromises the safety of the system
REPAIR: It's advised that damaged racking uprights are replaced rather than repaired to ensure safety compliance.
PREVENT: Most damage occurs within the first 600mm of the upright. Protect racking uprights from being damaged in the first place. Protection guards deflect and absorb impact before it can cause damage to the upright.
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