Author Archives: Maisie Greenfield

The Power of Preventative Maintenance – How to Reduce Downtime and Extend the Lifespan of Warehouse Racking

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We all know that preventative maintenance is better than reactive maintenance, as it reduces accidents and down time, plus the cost of damaged goods and repairs. However, determining the ideal level of preventative maintenance to achieve the best return on investment (ROI) can be challenging. Read how to focus on creating a pragmatic plan tailored to your workplace, specific risks, and budget.

We’ll highlight the primary advantages and outline essential steps to consider when developing your plan.

How a preventative maintenance plan can benefit your business.

  • Decreased Downtime and Reduced Repair Costs
    Regular maintenance helps identify potential issues before they lead to equipment failure. By addressing these issues proactively, downtime can be minimized, and the need for costly racking repairs can be reduced.
  • Increased Racking Life Expectancy
    Proper maintenance extends the working life of warehouse racking systems. By regularly inspecting and maintaining critical components, the overall lifespan of the racking can be prolonged, reducing the need for premature replacements.
  • Improved Equipment Efficiency and Quality
    Well-maintained warehouse racking systems operate more efficiently, allowing for smoother material handling processes and optimized storage capacity. Regular maintenance ensures that the racking is in optimal condition, minimizing the risk of accidents, product damage, and inefficiencies.
  • Less Damaged Goods
    Stored assets are often damaged when racking failure occurs resulting in not just the cost of unusable stock but also replacement cost and the impact on delivery and customer service.
  • Improved Safety
    A ROI will always include the wellbeing and safety of employees and by keeping equipment in good working order, accidents, injury, sick leave and claims should be reduced and ideally engineered out.
  • Maintaining Compliance and Following Regulations
    Racking systems are considered work equipment, and PUWER (Provision and Use of Work Equipment Regulations 1998) requires that they are maintained in good working order. Also the Health and Safety at Work Act 1974 is an overarching legislation which requires employers to provide a safe working environment. Regular maintenance, inspections, and repairs can help ensure that racking systems meet all these requirements.
  • Enhanced Corporate Reputation
    A preventive maintenance plan demonstrates a commitment to safety, quality, and operational excellence. This can enhance the reputation of your business and the overall brand image, leading to increased customer trust and potential business opportunities.

While companies have shown that an effective preventive maintenance program can deliver a better return on investment, it’s important to note that the specific ROI and cost savings will vary depending on factors such as the size and purpose of the warehouse, the complexity of the racking systems, the frequency of maintenance activities, and the training of employees.

To build the best preventive maintenance plan for your warehouse racking, here are some useful steps:

Understand your Racking Systems

Begin by gaining a thorough understanding of the warehouse racking systems in place. This includes the type of racking (e.g., selective, drive-in, push-back), their load capacities, and any specific maintenance requirements recommended by the manufacturer.

Identify Critical Components

Identify the critical components of the racking systems that require regular inspection and maintenance. This may include upright frames, beams, connectors, base plates, and safety accessories.

Determine Maintenance Frequencies

Determine the appropriate maintenance frequencies for each component based on factors such as usage intensity, load capacity, and environmental conditions. This will require consideration of goods being transported into and around the racking and the methods of transport with associated risks.  Some components may require more frequent inspections and maintenance than others.

Establish Maintenance Procedures

Define clear maintenance procedures for addressing identified issues. Ensure that the procedures align with manufacturer recommendations and industry best practices.

Assign Responsibility

Assign responsibility for the preventive maintenance plan to qualified personnel who have the necessary knowledge and skills. This may involve training existing staff or hiring external experts if required.

Implement a Tracking System

Implement a tracking system to record and monitor maintenance activities. This can be done using computerised maintenance management software (CMMS) or a simple spreadsheet. The tracking system should include details such as inspection dates, maintenance actions taken, and any follow-up requirements.

Schedule Regular Inspections

Now that you have defined what, why and how often things needs to be maintained, establish a schedule for regular inspections. Consider also the factors such as the workload of the warehouse, peak seasons, and any specific requirements of the racking systems. Regular inspections should be conducted at predetermined intervals to ensure timely identification and resolution of issues.

Develop Inspection Checklists

Create detailed inspection checklists that cover all critical components and potential issues. These checklists should include visual inspections for signs of damage, corrosion, misalignment, or other abnormalities. Additionally, consider using specialized tools such as load testers to assess the structural integrity of the racking systems.

Document and Analyse Findings

Document all inspection findings and maintenance actions taken. Analyse the data over time to identify recurring issues, trends, or patterns that may require adjustments to the preventive maintenance plan. This analysis can help optimize the plan and improve its effectiveness.

Continuous Improvement

Regularly review and update the preventive maintenance plan based on feedback, lessons learned, and changes in the warehouse operations including;

  • if materials and services can be deployed or sourced more efficiently and cost effectively,
  • should impact protection solutions be implemented or improved.
  • can storage or workflows be redesigned,
  • do employees require training.

Continuous improvement ensures that the plan remains effective in preventing major issues and optimising the lifespan of the racking systems.

Training for Warehouse Teams

Empowering your warehouse teams with adequate training is critical in supporting a preventative maintenance plan. Warehouse teams should be trained to recognize signs of wear, damage, or instability in the racking system. This includes understanding the importance of load limits, recognizing damaged components, and knowing when to report potential safety concerns. Training should also equip personnel with a clear protocol to follow in the event they encounter a safety issue. Encouraging an open reporting culture ensures that any observed problems are promptly communicated to supervisors or maintenance teams for swift resolution.

By following these steps, businesses can build a comprehensive and effective preventive maintenance plan for warehouse racking, leading to cost savings, improved safety, and increased operational efficiency.

Warehouse Racking Specialists

With four decades of industry leadership in the UK, Rack Group has been a trusted partner for businesses, enhancing the longevity of their racking systems while optimising safety and operations. Our comprehensive racking services cover the entire lifecycle, encompassing emergency repairs, maintenance, inspections, and training. Whether you require assistance in developing a preventative maintenance plan or support for specific aspects of your operations, Rack Group is here to help you.

📞 01226 78 44 88

📧 info@therackgroup.com

The Benefits of Local Businesses Partnering with Rack Group

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As an industrial storage business located in Yorkshire, you have a unique opportunity to tap into Rack Group’s valuable services that can transform local businesses and the way you manage your warehouse, and storage systems.

Rack Group, head quartered in Barnsley has decades of experience and expertise in industrial racking, offering a range of benefits that can significantly benefit your business operations. In this article, we’ll explore the advantages of partnering with Rack Group’s industrial racking experts right in your backyard.

Rack Group, Industrial Racking Experts

Local Presence, Global Expertise

Rack Group’s roots are firmly planted in Yorkshire, as a trusted local partner. However, their expertise extends far beyond the region. With over 40 years of industry experience, Rack Group has served businesses across the UK and beyond.

This means you get the best of both worlds: the personal touch of a local partner and the world-class knowledge of a global expert.

Lightning-Fast Response Times

Rack Group’s reputation for being fast and responsive is one of their standout qualities. In the fast-paced world of warehousing, time is of the essence Having Rack Group just around the corner translates to lightning-fast response times. Whether it’s urgent inspections, timely repairs, or immediate consultations, their local presence ensures that help is never too far away.

This rapid response capability minimises disruptions to your daily operations and keeps your warehouse running smoothly. Rack Group also provide a range of dedicated training courses which can easily be provide either at the dedicated training centre in Barnsley or onsite.

Cost-Effective Collaboration

One of the many benefits of working with Rack Group as a local business is the reduction in travel cost and time. With their close proximity to your location, you can eliminate the need for extensive travel or transportation costs associated with sourcing expertise from afar.

This cost efficiency can have a positive impact on your bottom line, allowing you to allocate resources more effectively.

Boosting Local Economy

By choosing Rack Group, you’re not only optimising your warehouse operations but also supporting a local business in Yorkshire. Your collaboration contributes to the growth and sustainability of the local economy, fostering a sense of community and shared prosperity.

It’s a win-win scenario where your business benefits, and so does the region you call home.

Tailored Solutions with Local Insight

Rack Group understand the unique challenges and opportunities that businesses in Yorkshire face. This local insight allows them to offer tailored solutions that are specifically designed to sourcing new premises which requires local knowledge, and regional considerations.

Sustainability

Rack Group is committed to sustainability, and their local presence aligns perfectly with environmentally responsible practices. With reduced travel distances for their team, you’re helping to lower carbon emissions and support eco-friendly initiatives.

Rack Group further contributes to a greener future as their barrier solutions are non-toxic and fully recyclable. By choosing Rack Group as your partner it will bolster your dedication to sustainability while also benefiting from a greener approach to business.

No Nonsense Cost Savings Approach

Rack Group’s services are designed to save you both time and money. By optimising your storage solutions and extending the lifespan of your racking systems, they help you avoid costly repairs and replacements.

Their proactive approach means that potential issues are identified and addressed before they become expensive problems.

Trusted Neighbourhood Experts

Having Rack Group as your local industrial racking experts means you’re working with a team deeply ingrained in the Yorkshire community. They’re not just service providers; they’re trusted neighbours who understand the importance of local business relationships.

When you choose Rack Group as your local industrial racking experts in Yorkshire, you unlock a multitude of benefits that go beyond traditional service providers. With cost-effective collaboration, rapid response times, and the support of a local business, you’re making a smart choice for your warehouse operations. Your partnership with Rack Group not only optimizes your business but also bolsters the local economy and contributes to a sustainable future for all local businesses.

For local businesses, whether you need assistance with racking inspections, protection, repairs, installation or training, Rack Group’s industrial racking experts are ready to help. Don’t miss out on the opportunity to transform your business with Rack Group’s expertise and local services!

For more information on The Rack Group’s products and services, please contact us today for further details.

The Main Reasons Behind Racking Collapse and How To Avoid These Risks

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Warehouse safety is of paramount importance in any industrial setting. One critical aspect that demands attention is the integrity of racking systems.

Unfortunately, racking collapses can lead to catastrophic consequences, posing risks to personnel, operations and inventory. To prevent such disasters, let's delve into the most common causes of racking failures, explore examples and most importantly the prevention of racking collapse.

Collapsed Racking Image Source TechRescueWMFS  Racking_collapses_1  Picture2

 

1. Racking Incorrectly Installed

One of the leading culprits behind racking collapses is improper installation. When racking systems aren't assembled correctly, they lack the necessary stability to bear the weight they are designed for. Substandard installation often involves misaligned beams, loose connections, or insufficient anchoring to the floor or wall. 

Example: In a warehouse, a racking system was hastily installed without adhering to the manufacturer's guidelines. As a result, the beams weren't adequately secured, leading to an eventual collapse when the load capacity was exceeded. 

 

2. Overloaded Pallets and Beams

Either incorrect evaluation of weight limits or ignoring weight load notices. Pushing the limits of a racking system by overloading pallets and beams, is an invitation for disaster. Exceeding the maximum weight capacity compromises the structural integrity of the racking, increasing the risk of failure. 

Example: Even though the weight load notice stated the weight load capacity of the racking, pallets were stacked beyond the recommended load-bearing capacity of the racking. This constant overload weakened the system, eventually resulting in a catastrophic collapse. 

 

3. Impact from Material Handling Equipment

The bustling environment of a warehouse often involves the use of material handling equipment like forklifts and reach trucks. Accidents and collisions with racking systems can cause damage that goes unnoticed, and even small bumps will gradually weaken the structure over time. 

Example: A forklift operator accidentally backed into a rack, causing a slight dent in the upright. While seemingly minor, this impact weakened the racking's structural integrity, leading to its eventual failure during regular operations by maxing its now weakened load potential or from further minor bumps. 

 

4. Racking Reconfigured and Not Re-Inspected for Safety

Warehouse dynamics change over time, prompting reconfigurations of racking systems. However, these alterations are not always followed by safety inspections. Neglecting to reevaluate the integrity of the racking after reconfiguration can lead to unforeseen vulnerabilities. 

Example: Due to an increase in new product lines, a warehouse decided to rearrange its racking layout. However, the safety inspection was overlooked, and the new configuration was never thoroughly assessed for structural soundness, eventually leading to a collapse. 

 

5. Racking Components Not Repaired Properly

When racking components sustain damage, repairs must be carried out promptly and professionally. Cutting corners or using makeshift fixes compromises the system's overall strength and reliability. 

Example: In an attempt to save on costs, a warehouse maintenance team attempted to repair a bent beam by straightening it. This inadequate repair rendered the beam unstable, ultimately contributing to the racking collapse. 

 

How can you minimise the Risk of Racking Collapse? 

Qualified Installation, Maintenance, and Inspection Teams

The foundation of a robust racking system begins with a proper installation by qualified experts. Engaging professional installation teams ensures that racking systems are assembled in accordance with manufacturer guidelines, and following EN Regulations and SEMA Guidelines, to ensure the best structural integrity from the start. 

Proper installation ensures that racking systems can safely withstand the intended loads and daily operations. It encompasses aligning beams accurately, securely fastening components, and anchoring the racking securely to the floor or wall. 

Routine inspections involve comprehensive checks of the racking's structural integrity, including uprights, beams, and connections. Inspections can be undertaken by an internal trained employee while annual inspections by external qualified inspectors. All annual inspectors should be trained to follow EN15635 Standard and PUWER Regulations, in identifying potential vulnerabilities and assessing load-bearing capabilities. 

Sufficient Training for Warehouse Teams

Empowering your warehouse teams with adequate training is a critical defence against racking collapse. Educating personnel on what to look for and the appropriate actions to take upon spotting an issue can prevent potential catastrophes. 

  • Comprehensive Awareness: Warehouse teams should be trained to recognize signs of wear, damage, or instability in the racking system. This includes understanding the importance of load limits, recognizing damaged components, and knowing when to report potential safety concerns. 
  • Immediate Action Plan: Training should equip personnel with a clear protocol to follow in the event they encounter a safety issue. Encouraging an open reporting culture ensures that any observed problems are promptly communicated to supervisors or maintenance teams for swift resolution. 
  • Ongoing Education: Safety training should be a continuous effort, ensuring that all personnel, including new hires, are well-informed about warehouse safety practices. Periodic refreshers and updates on industry best practices keep the workforce vigilant and informed. 

Infographic (3)In conclusion, mitigating the risk of racking collapse is a multi-faceted approach that relies on professional installation, regular maintenance, and diligent inspections. Equally important is providing thorough training to warehouse teams to recognize potential hazards and respond swiftly to ensure a safe and secure workplace environment. By implementing these strategies, warehouse managers can proactively protect their facility, personnel, and valuable inventory from the threat of racking failures. 

Rack Group have over 40 years’ experience in industrial pallet racking design, installation, repair and inspections, while providing training to upskill customer inhouse teams. Contact us for advice, and quotes for training, installations and inspections. 

 

Simplifying Safety Barrier Systems: Making Informed Choices for Your Warehouse

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In a recent webinar, experts from across IWS Group of companies came together to shed light on the importance of safety barrier testing and how to make informed decisions when selecting them.

In particular, the significance of PAS 13 impact rating, choosing the right impact protection for your warehouse risks, and saving on repair and maintenance costs.

This article aims to summarize the key points discussed during the webinar and provide valuable insights for warehouse decision-makers, facilities managers, and health and safety professionals.

 

DISTRIBUTOR INVITE

 

Understanding the Importance of PAS 13

PAS 13 is a globally recognised guidance, established by the British Standards Institutes (BSi) and the Health and Safety Executive (HSE). It serves as a benchmark for safety barriers used in industrial workplaces.

It was explained that the use the PAS 13 BSi guidance is the foundation for IWS Group product testing to benchmark and validate that their barriers comply with PAS 13. Also to further seek verification from an independent testing house, such as TÜV Nord.

PAS 13, testing covers both horizontal barriers and vertical posts, to be impact tested ensuring comprehensive compliance. Testing involves impacting the barriers and measuring their deflection and force transfer. By adhering to PAS 13 standards, customers can have confidence in the reliability and quality of the safety barriers they choose.

 

Choosing the right impact protection for your specific warehouse risk

Safety barriers play a crucial role in protecting people, property, and stock in warehouse environments. However, it was raised that navigating the market and choosing the right safety barrier system can be a daunting task. It was agreed that when selecting safety barriers, decision-makers must thoroughly understand their warehouse environment and the areas that need protection. This includes identifying walkways, stock zones, and deflection zones. Deflection zones are essential for ensuring the safety of individuals by accounting for the distance a barrier will deflect upon impact. Different manufacturers offer varying deflection zones based on factors such as forklift types, speeds, and loads. Comparing barrier test data is key, but that can be challenging as many are not comparable, due to either not testing to PAS 13 and are not third party accredited. Consulting with experts and asking the right questions is crucial in determining the most suitable solution for a specific warehouse.

 

Simplifying Testing Data

Understanding testing data can also be challenging, especially when it involves complex terms like energy and kilojoules. To address this issue, the webinar participants introduced a simplified approach called “Safety Simplified.” This approach provides customers with straightforward information about the energy levels their products can withstand in real world terms. By customers knowing the maximum loads and speeds of their forklifts, they can easily interpret the performance of safety barriers to identify which best meet their needs.

Infographics2

Download the “Safety Simplified” infographic to clearly show barrier performance in real world situations.

 

Avoiding the Cost of Over-Engineering and Underperformance

The webinar addressed the common challenges faced by customers in the market when selecting safety barrier systems. The marketplace offers a wide range of safety barrier systems with varying prices and performance levels. It is important to avoid “over-engineered” products, as different environments require different specifications. For example, an airport can require far higher specification and performance of barriers in comparison to inside a warehouse. Also purchasing low cost, untested products may result in frequent replacements and compromised safety. Therefore it is crucial to invest in safety barriers that match the specific needs of a workplace.

 

Availability and Lead Times

Lead times can significantly impact the development timetable of a warehouse either from construction or ongoing risk management of an existing workplace. It was stressed to check lead times before purchasing which can often vary between weeks and many months and to plan this detail into your risk management strategy and planning.

The panelists reassured the audience that tested safety barrier products from Brandsafe have an average lead time of four weeks. As a UK manufacturer, Brandsafe has invested in its manufacturing process to meet customer requirements efficiently with warehouses in the UK, Central Europe and the USA for rapid response and worldwide product availability.

 

Saving on repair and maintenance costs

All the panelists agreed that choosing the right safety barrier system for a warehouse requires careful consideration of factors such as budget, durability and risk. It was also made clear that choosing polymer barriers over metal had several benefits.

The flexible barrier design and polymer material are engineered to absorb the load of impact, away from a vehicle and ground fixings to reduce damage and repair time, unlike metal barriers.

The benefits from such a design means customers will lower their repairs and maintenance cost compared to metal barriers and reduce vehicle impact damage and downtime. Maintenance is further lowered as these polymer barriers don’t rust, corrode, fade or require re-painting, and only need replacing after frequent, major impacts have occurred. They are also non-toxic and suitable for use in food production and freezer environments.

It was stressed that budget constraints can force compromises on durability and longevity. However, with the Brandsafe range of products, customers can find the perfect balance between cost-effectiveness and meeting their specific needs.

 

Key Considerations for Decision Makers

It was wrapped up with advice for decision makers, including facility managers, health and safety managers, and distributors, to assess their environment, determine what needs protection (people, property, and stock), map out walkways, vehicle flow and stock zones, and consider deflection zones. Then review PAS 13 tested and third party accredited barrier products to be confident your risk assessment is best supported by products you can trust.

A final point raised was sustainability is also a critical consideration to ensure long-term viability. Brandsafe barrier range not only offer 100% recyclability but also provide replacement parts, allowing for easy maintenance and extended product lifespan.

For more information view our range of products or contact us for advice or a quote.

📞 0044 1226 78 44 88
📧 info@therackgroup.com

 

Become a Distributor

The webinar highlighted the benefits for distributors who deal with safety barriers as part of their portfolio or wish to add them. Companies were invited to join as a distributor or reseller of Brandsafe barriers to help their customers create a safe and productive workplace.

For more information visit our distributor page.

The Rise of Polymer Over Metal Impact Barriers: The New Standard in Strength and Safety

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A crucial aspect of achieving a secure and efficient workplace environment is selecting the right impact barriers, that can effectively safeguard your facility from potential risks.

Traditionally, metal impact barriers have been the go-to choice, but in today’s workplace, an innovative alternative is proving to be just as strong, if not stronger and with many more advantages – polymer impact barriers.

 

Strength Tested and Accredited

The perception that metal barriers are inherently stronger than polymer barriers is being challenged with groundbreaking research and rigorous testing. Polymer impact barriers have undergone comprehensive testing by reputable accrediting bodies, proving their formidable strength. Their accredited performance data demonstrates that they are well-suited for specified purposes, including withstanding high-impact scenarios.

 

No alt text provided for this image

Flexibility in Design for Maximum Safety

No alt text provided for this imageThe automotive industry has taught us valuable lessons about impact resistance. Modern cars are designed with more flexible materials and structures to absorb and disperse impact forces, ensuring the safety of drivers and passengers. In the same vein, polymer impact barriers are strategically engineered with this principle in mind.

A metal barrier will typically upon impact be scratched or dented as well as the vehicle. Unlike polymer barriers, a metal barrier also relies more on the impact force to be absorbed through the floor fittings which can in addition damage the floor and require further repairs. The flexible nature of polymer barriers allows them to absorb and distribute impact energy more evenly. This intelligent design not only enhances safety but also prolongs the lifespan of the barriers, floor fittings and vehicles, reducing the need for frequent replacements, repairs and maintenance.

Proven Usage of Polymer Barriers Across Industries

Polymer impact barriers have emerged as game-changers in high impact protection across various industries. From bustling airports to busy warehouses, these barriers have proven their mettle in safeguarding critical infrastructure and personnel.

The adaptability of polymer barriers makes them ideal for diverse applications. Whether it’s guiding traffic, protecting equipment, or enhancing pedestrian safety, they rise to the occasion with unmatched performance.

 

Greater Environmental Protection

In addition to their strength and safety benefits, polymer impact barriers have a compelling edge over traditional metal barriers when it comes to their environmental impact. The manufacturing process of polymer barriers involves less energy consumption and generates fewer emissions, contributing to a reduced carbon footprint. Polymer barriers can be 100% recycled and reprocessed, adding to their eco-friendliness. Also the lightweight nature of polymer barriers translates to significant advantages in transportation. During shipment, less fuel is consumed due to reduced weight, resulting in lower greenhouse gas emissions. Moreover, the lighter weight makes handling and installation of polymer barriers easier and more efficient, saving time and resources on-site.

The durability of polymer barriers further contributes to their environmental appeal. Their ability to withstand harsh conditions, including exposure to extreme weather and corrosive agents, means they have a longer lifespan than many metal barriers.

 

The Advantages in Summary

  1. Proven Strength: Rigorous testing and accreditation validate the strength and reliability of polymer impact barriers, putting them on par with metal barriers.
  2. Smart Design for Enhanced Safety: The flexible design of polymer barriers allows them to absorb impact energy, minimizing potential damage and protecting personnel.
  3. Wide Industry Applicability: Polymer barriers have been successfully implemented across various sectors, attesting to their versatility and effectiveness.
  4. Cost-Effective and Long-Lasting: With their robustness and extended lifespan, polymer barriers save on replacement costs while maintaining top-notch protection.
  5. Eco-friendly: Beyond their strength, polymer barriers boast eco-advantages, with lower carbon emissions, recyclability, longevity and less maintenance.

 

In conclusion, while it is proven polymer barriers perform as well as metal barriers, the question asked by employers should not be “are polymer barriers stronger than metal barriers” but which barriers will best support your specific risk and cost.

With many different grades of metal and polymer barriers available, they will all perform differently, so it is essential to review the performance of each to assess suitability. This can be achieved by reviewing test data, and ensuring it is third party accredited. Look out for BSI PAS13 code of practice which is a globally recognised and respected guidance for manufactures to follow, as best practice when testing their products. PAS13 requires consistency in testing, so it should provide you with the ability to compare products more easily.

From warehouse to health and safety managers, it’s time to embrace the advancements in impact barrier technology. Polymer impact barriers have proven their strength, efficiency, and cost-effectiveness, making them a reliable choice for ensuring the safety of your facility. By choosing polymer impact barriers over metal barriers, you also make a tangible contribution to environmental preservation and sustainability.

IWS Group is committed to pioneering workplace safety with our Brandsafe® range of polymer impact barriers which are:

 

Finding the right polymer barrier for your risk

No alt text provided for this imageIt can be challenging to interpret barrier testing data, and especially when manufacturers are not consistent or third party accredited. To help you identify which barriers are suitable to address your specific risk, we have developed a user-friendly approach called Safety Simplified.

Download our infographic which presents our test data in a clear format, so you can easily understand the performance of our products. This will enable you to make better informed decisions based on your specific forklift truck specifications, and loads.

Simplifying barrier performance – Infographic – The Rack Group

Rack Group partners with Capita for Seamless Warehouse Relocation

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About Capita

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.

Barnsley

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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Move or not to move – How to decide if a mezzanine is the best solution

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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

  1. 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.
  2. 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.
  3. 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.
  4. 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.
  5. 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.

Picture 4

Negatives of Installing a Mezzanine Floor

  1. 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.  
  2. 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.
  3. 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?

When selecting a mezzanine for your warehouse, there are several key factors to consider. Here are some of the most important considerations:

Purpose and Use

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.

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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.

Space-Saving Strategies: How to Choose the Right Mezzanine for Your Business

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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.

Mezzanine design and install

 

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.

Picture 33. Mezzanine Floor Installations Rack Group1. Mezzanine Floor Installations Rack Group

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.

To learn more about the different types of mezzanine installations and which option is best for your warehouse, schedule a consultation with our experts.

What to Look for in a Warehouse Racking Inspector

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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.

Pallet Racking Training Rack Group

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:

  1. 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.
  2. 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.
  3. 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.
  4. 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. 

IWS Group is resetting the bar on impact safety, with PAS 13 barrier range certified by TÜV Nord

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IWS Group,  has impact tested its Brandsafe® range of polymer safety barriers according to the rigorous PAS 13 code of practice, which has been third-party accredited by TÜV Nord, an internationally recognised seal of quality.

The testing process measures the impact resilience of these barriers, enabling customers to make informed choices about the right systems for their needs. By adhering to PAS 13, IWS Group is among a select few companies committed to the highest safety benchmark in the industry today.

Testing of the barrier range took place in April 2023 at an IWS subsidiary,  Rack Group in Barnsley, where the barriers are designed and manufactured. A custom-built pendulum was used to strike the barriers at various points to measure the resilience of the barrier. How much force the barrier could take, as well as how much it deflected, was recorded on-site using high-spec measuring equipment.

Commenting on what the testing means for customers, Susy Keating, MD at Brandsafe said, “This testing is an important step for customers looking to purchase impact protection barriers for their workplace. Knowing what impact forces a barrier can take, as well as ensuring that data is independently certified by a reputable third party, is a vital factor in choosing the right barrier. For too long impact protection has been over-engineered, over-priced and overly complicated. It’s time to reset the bar on what impact protection ultimately comes down to, which is keeping people and products safe.”

Stuart Ovington, MD of Rack Group said, “TÜV Nord independently verifying that our testing abided by the PAS 13 guidelines serves as a testimonial to our teams here at IWS Group, as well as the quality of our polymer barrier range. Not every barrier manufacturer undertakes product testing to this level, so we are proud to be amongst the industry leaders. Our barriers are shown to be high performing, long-lasting and can withstand greater impacts than similar, industry-leading products. In addition, we can create bespoke designs quickly to suit individual needs and, with short lead times, provide a cost-effective solution at the highest standard.”

Matt Mason, Group Design Manager at IWS Group added, “We undertook this activity to prove the capability of our barrier range and, with TÜV Nord witnessing, it confirms that our internal testing procedure adheres to the industry code of practice.

Testing is conducted on a purpose-built impact pendulum rig designed and commissioned entirely by IWS Group, which simulates real world impact energies of material handling vehicles travelling at different speeds and provides physical proof to the capability of our products.

The pendulum strikes barriers at various pre-determined locations to measure the level of energy the barriers can withstand, how much deflection they display under impact and how much force is transferred to the ground fixings and concrete. Testing also defines the distance behind barriers that is considered the ‘safe zone’ for the barrier to deflect in to, which is identified during installation of the barrier by visual floor markings.

All testing was conducted with UKAS calibrated measuring equipment such as high-speed cameras, torque wrenches, load cells and industrial weigh scales to ensure confidence in every result witnessed.”

To find out more about the Brandsafe® polymer barrier range and the impact safety testing that has been carried out, visit brandsafeprotection.com or request the technical data by emailing sales@brandsafeprotection.com.

Safety, simplified.

 

How are these barriers designed to withstand impact?

The flexible barrier design and polymer material are engineered to absorb the load of impact, away from a vehicle and ground fixings to reduce damage and repair time, unlike metal barriers.

The benefits from such a design means customers will lower their repairs and maintenance cost compared to metal barriers and reduce vehicle impact damage and downtime.

Maintenance is lowered as these polymer barriers don’t rust, corrode, fade or require re-painting, and only need replacing after frequent, major impacts have occurred.

They are also fully recyclable, non-toxic and suitable for use in food production and freezer environments.

About IWS Group

IWS Group is a family of market-leading product brands, manufacturers and service companies, providing essential services and supplies to the logistics, material handling and other industrial sectors across Europe and beyond. The group consists of four companies:

Impact Safety Specialist, Brandsafe

Industrial Racking Specialist, Rack Group

Visual Management Manufacturer & Specialist, Beaverswood

Exclusively Trade Shelving & Storage Specialist, Anco 

Discover more at www.iws.group