Rack Group’s Training Courses Achieve Prestigious Assured by RoSPA Qualifications

Posted on 12 December 2023 by Maisie Greenfield

Rack Group, a leading name in innovative racking solutions, is thrilled to announce that our racking inspection and maintenance training courses have received the esteemed Assured by RoSPA Qualifications. This recognition signifies a remarkable achievement in our training courses to enhance workplace safety and to upskill internal teams to inspect and repair racking systems effectively.

Assured by RoSPA Qualifications, a nationally recognised Awarding Organisation, provides a stamp of assurance that our courses meet the highest standards in health and safety.

Stuart Ovington, Managing Director of Rack Group, expressed his enthusiasm about this accomplishment, stating, “We are delighted to receive the Assured by RoSPA Qualifications for our racking inspection and maintenance training courses. This recognition reflects our commitment to delivering top-notch training that not only enhances the skills of employees but also ensures the highest standards in safety and competence. This qualification is a testament to the quality and relevance of our training programs, ensuring that they are pitched at the appropriate level and delivered with excellence.”

Stuart also added that “Course Assurance from RoSPA Qualifications instils confidence in our stakeholders, including customers, employees, and partners, by guaranteeing that:

The course content contains relevant and up-to-date information.
The course is pitched at the appropriate level for effective learning.
The course meets high standards for trainer competence and overall quality.

The RoSPA Qualifications ‘stamp of assurance’ is a recognition of our commitment to delivering excellence in workplace safety.”

Rack Group remains dedicated to advancing workplace safety and empowering teams with the skills needed to maintain and enhance racking systems securely.

END

About Rack Group

Rack Group is a pioneering company specializing in racking solutions, offering innovative products and services to optimize warehouse spaces. With a focus on safety and efficiency, Rack Group designs, and installs racking systems and mezzanine floors and additionally racking inspection, maintenance, protection and training solutions, ensuring clients’ storage systems meet the highest standards and longest lifespan. Visit www.rackgroup.com for more information.

Rack Group training courses

Having the in-house personnel with the skills to quickly spot, assess and repair your racking, can have significant savings and improve safety and productivity. The Inspection course empowers internal teams to provide regular internal checks of racking to ensure it stays safe to support your stock and remains structurally sound. Our racking maintenance training, provides your team with the skills and knowledge required for them to safely carry out repairs on damaged racking systems with confidence.

About RoSPA Qualifications

RoSPA is a not-for-profit organisation that has worked for more than 100 years to help people recognise and reduce their risk of accidents, at home, on the road, at work and at leisure. Their goal is to enable everyone to live their lives to the full, safely. Visit About Us – RoSPA for more information.

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

Posted on 17 October 2023 by Maisie Greenfield

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 Main Reasons Behind Racking Collapse and How To Avoid These Risks

Posted on 14 September 2023 by Maisie Greenfield

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.

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.

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

Posted on 8 September 2023 by Maisie Greenfield

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.

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.

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

Posted on 6 September 2023 by Maisie Greenfield

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.

Flexibility in Design for Maximum Safety

The 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

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

Tested to PAS 13 and third party accredited by TUV Nord
Our barriers outperform similar products in the market
Rapid customisation to fit a customer’s unique environment
Shorter lead times, than any other providers

Finding the right polymer barrier for your risk

It 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

Racking Repairs Traffic Light Code

Posted on 30 July 2022 by Maisie Greenfield

Racking damage and repair

Once damage has been identified on a racking system, you should take action according to the SEMA traffic light code of practice.

Red Risk - Very serious damage requiring immediate action

Amber Risk - Hazardous damage requiring action as soon as possible

Green Risk - Requiring surveillance only

These levels of damage will be highlighted in your racking inspection, which you should have at least once every 12 months.

You should also ensure your in-house teams regularly inspect and monitor your storage systems to identify damage early.

What does a Red Risk on racking mean?

Red risks on racking are situations where a critical level of damage is identified. The area of racking should be immediately offloaded and isolated from future use.

The racking can be re-used when the necessary repair work is carried out and the system is re-inspected for safety. Such repair work would usually be by replacement of the damaged component.

You should have a method of isolating areas to ensure that they do not come back into use before the repair work is carried out. For example, a particular bay could be offloaded in the presence of the inspector and roped off to prevent further use.

What does an Amber Risk on racking mean?

An amber risk on racking would identify an area where the damage was sufficiently severe to warrant remedial work, but not so severe as to warrant the immediate offloading of the rack.

Once load is removed from a damaged component, the component should not be reloaded until repairs have been carried out.

You should have a method of isolating such racks to ensure they do not come back into use until the necessary racking repairs have been carried out. The equipment should then be certified as safe before the rack is reloaded.

You could also use dated racking damage report tags to indicate the racks are not to be used until repaired.

Any racking with an AMBER RISK category damage should be re-categorised as RED RISK if remedial work has not been carried out within four weeks of the original identification.

What does a Green Risk on racking mean?

Green level damage on racking indicates the rack does not need to be offloaded or repaired immediately. This category indicates the racking components are considered safe and serviceable.

Such components should be recorded as suitable for further service until the next management inspection. The components should be clearly identified for specific re-examination and reassessment at future inspections.

Exceeding the green level should be considered damage and causes risk to the racking system.

When do I need to repair racking damage?

Damage to racking needs to be prioritised in order of risk category.

Red risk damage should be first offloaded and segregated from being used. Repair work will need to be booked in as soon as possible before the racking can be reused.

Amber risk damage should be repaired within four weeks, otherwise the racking needs to be immediately offloaded and unused until repair work is carried out.

Green risk damage should be monitored for any deterioration at regular in house inspections. If there are any changes to the damage, the appropriate action should be taken depending on the new category of risk.

To find out more about common types of racking damage and what you should do about them, check out our maintenance and repairs page here.

Do your teams know what to look for on their regular in-house inspections? Ensure they have the skills and the knowledge to keep your warehouse safe and operational. Visit our training courses page here.

Chris Rodger New Head Of Sales At Rack Group

Introducing Our New Head of Sales

Rack Group is thrilled to announce the appointment of Chris Rodger as the company’s new Head of Sales.

Read on

Rack Group Training Courses Achieve Prestigious Assured By RoSPA Qualifications

Rack Group’s Training Courses Achieve Prestigious Assured by RoSPA Qualifications

Rack Group, is thrilled to announce that our racking inspection and maintenance training courses have received the esteemed Assured by RoSPA Qualifications.

Read on

Unlock the hidden potential of your warehouse space

In this blog post, we will provide you with practical insights, expert advice, and proven strategies to help you unlock the hidden potential of your warehouse space.

Read on

Weight Load Notices

Posted on 2 July 2022 by Maisie Greenfield

Do I need a Weight Load Sign for my racking?

PUWER regulation 4 requires that work equipment is:

suitable for its intended purpose
selected so that the risks to the health and safety of users can be managed
used only for the operations for which it is suitable

This regulation also states that work equipment should be accompanied by information, including user instructions.

Companies using racking can demonstrate they are abiding by this regulation by displaying signs specifying the safe working limits of the equipment.

Weight Load Notices are there to advise colleagues on the safe load limit for the storage system. This is to ensure the racking is not overloaded and therefore unsafe to use.

What does a Weight Load Sign need to include?

The safe working load limit of the rack needs to be displayed in a conspicuous location 2m from the floor, made from corrosion-resistant material, and should include the following information:

Suppliers name
Date supplied with contact information
Safe working load of each shelf
Safe working load of the bay*
Height to first beam
Beam pitch
Safety and warning signs

*IMPORTANT: The bay load is there to advise the safe limit for the whole system at one time and can often be less than the total of each shelf limit.

What happens if I alter the beams on my racking?

Whenever racking is reconfigured, the system should be inspected for safety and the Weight Load Notice updated if necessary.

If the racking layout is changed and the safe working limits are not recalculated, you could be providing inaccurate information to your warehouse teams and therefore risking the safety of the system.

What if I don't have a Weight Load Sign?

New racking should be supplied with Weight Load Signs upon completion of the install and before the racking is used. Newly installed racking needs to be inspected before it is operational. This inspection should identify any racking where a Load Sign is not displayed.

How do I calculate the Safe Working Load of my racking?

Every manufacturer design their racking to different working limits. Therefore calculating the Safe Working Load of racking is not a one-size-fits-all process.

To accurately calculate your Safe Working Load, you will need to supply us with the following information:

Width of the bay
Type of beam (open or box)
Beam dimensions (width and depth)
Frame dimensions (height and width)
Vertical beam pitch (height of each beam from the floor)
Upright duty (usually stamped on the upright)

There may be other information that's required. Please get in touch with our team if you'd like to order Weight Load Signs.

Introducing Our New Head of Sales

Rack Group is thrilled to announce the appointment of Chris Rodger as the company’s new Head of Sales.

Read on

Rack Group’s Training Courses Achieve Prestigious Assured by RoSPA Qualifications

Rack Group, is thrilled to announce that our racking inspection and maintenance training courses have received the esteemed Assured by RoSPA Qualifications.

Read on

Unlock the hidden potential of your warehouse space

In this blog post, we will provide you with practical insights, expert advice, and proven strategies to help you unlock the hidden potential of your warehouse space.

Read on

Causes of Racking Damage

Posted on 15 June 2022 by Maisie Greenfield

Racking damage and how to prevent serious accidents

Racking systems are vital for efficient warehouse storage and operations. Not only are they a big investment, they are also used extremely often every day. This makes them vulnerable to being hit by moving vehicles and pallets.

Minor damage might seem like a small risk initially, but left unmonitored and these little bends can worsen into serious damage.

Ignoring serious damage doesn't make the risk disappear. If left untreated, racking can buckle and collapse, causing a domino effect and knocking whole aisles of racking over.

So, what are the main causes of racking collapse?

Let's look at some of the most common reasons why racking collapses, plus tips on how to reduce the risk:

Racking incorrectly installed

Unqualified installers can build racking incorrectly, compromising its safety. Ensure you always use a qualified, experienced racking installation company that can guarantee installation to the manufacturers instructions.

Racking uprights should always be bolted to the floor using at least two fixings per base plate. Cutting corners won't save time or money long term. Not installing racking properly will likely lead to accidents and legal cases brought against the warehouse owner.

You should also make sure you're choosing the right type of racking for your products and operations. Courtesy of Dexion, we have a handy guide on how to choose warehouse racking.

Overloaded pallets and beams

Every beam of racking has a weight load limit. These limits should be clearly displayed for warehouse teams to see. They should also have training if needed to make sure they understand, and abide by, these limits.

It is a legal requirement to display Weight Load Notice Signs on every aisle of racking. Missing, damaged, or incorrect Weight Load Notice Signs will be identified during your annual racking safety inspection. These should be installed as quickly as possible to prevent possible accidents caused by incorrect loading of pallets and beams.

Impact from material handling equipment

MHE (Material Handling Equipment) frequently moves pallet and stock around the warehouse. Manoeuvring narrow aisles of racking with large, bulky and heavy pallets can often lead to bumps and scrapes with the racking uprights, beams and bracing.

Without barriers and guards, racking can be quite vulnerable to these types of collisions. This can lead to buckling and tears in the components, and ultimately racking collapse if left unrepaired.

Reduce this risk of racking collapse by installing racking protection barriers and guards. Check out our racking protection guide here.

Racking reconfigured and not re-inspected for safety

It's really common for warehouses to change their operations or alter capacity. One of the great benefits of using storage systems like pallet racking is that they can be reconfigured easily.

The risk here is that making any changes to racking beam levels can change the Weight Load Limit. If racking is altered without an experienced engineer, there is a danger that the Weight Load Notice Sign is not updated accordingly.

This can then lead to unsafe working loads of the beams, and potential danger of racking collapse. Ensure all racking is altered by a professional, the weight load limit is recalculated, and the Weight Load Notice Sign is updated to reflect the changes.

Racking components not repaired properly

Repairing racking using in house teams is not necessarily a danger to the racking itself, assuming the person has the relevant skills and training to do so.

Where the risk lies is when racking components are repaired by unskilled and untrained individuals. 'Repairing' torn components by welding patches over the damage is an example of risky repairs and can lead to serious damage.

Repairs are categorised by a traffic light system, created by SEMA. Your annual racking safety inspection will identify any damage, as well as which category they call under. Make sure you follow all guidance from your inspector to keep your warehouse operational and your team safe.

How can you minimise your risk of racking collapse?

Make sure you use qualified installation teams to install and alter any racking systems to the manufacturers instructions
Book a racking safety inspection at least once a year to capture issues and damage
Repair damage as soon as is required, according to the SEMA traffic light coded system
Ensure your teams have sufficient training to know what to look for and what actions to take if they spot an issue

Visit our Maintenance & Repairs page to browse more types of racking damage, and what steps you need to take next.

Recently had an inspection? Send us your report and we can quote your repair work.

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5 Ways to prolong the life of your racking

Posted on 10 May 2022 by Maisie Greenfield

How to prolong the life of your racking

Let’s face it, storage equipment doesn’t come cheap. Racking plays an essential role in keeping your warehouse operational, yet can also be the reason why you encounter disruptions and down time. This article delves into some of the ways you can get the most out of your racking, ensuring it lasts for years to come.

Racking has a very important job to do. Storage equipment is designed to hold tremendous amounts of warehouse stock. This stock is precious, as are your people who work in and around it. It’s also a huge investment for your business. Whether you choose to buy brand new, or source some quality second-hand systems, you’ll want to prolong the life of your racking for as long as possible to get a good ROI.

If well maintained, industrial storage equipment can last for years and years. This of course depends on how busy your warehouse is, the types of products you are storing, and the environment your racking is stored. It also depends on how well you treat it.

This brings us to our first tip on how to prolong the life of your racking:

1. Make sure your warehouse operators are fully (and regularly) trained

This may sound obvious but the main source of damage to racking is due to impact from Material Handling Equipment such as forklift trucks. This seems like a sensible place to start when looking at ways to prolong the life of your storage equipment. Ensure your teams are not only trained when they join your company, but have regular refresher training to keep their skills sharp.

It’s also important to ensure your team is confident working with the racking itself. One example could be with the weight load limits on your particular type of pallet racking. Displaying weight load notices at the end of every aisle of racking enables your team to quickly check limits and ensure they are followed. Overloading racking, or storing pallets with uneven distribution of weights is one way storage systems can be weakened, potentially leading to racking collapse.

So, you’ve had your racking installed by a top-notch team of qualified installers, your MHE drivers are fully trained and your stock is safely loaded. It’s now time to talk about protecting that lovely new racking installation of yours. As the classic saying goes, prevention is cheaper than the cure. Which brings us to tip number two:

2. Protect racking uprights before damage occurs with guards

Whether you prefer metal guards, or hard-wearing polymer guards, choosing to protect your racking uprights will save you money in the long-run. Guards can cost as little as £10 each, protecting the most vulnerable part of the upright. In comparison, a full upright replacement can cost up to £500.

Racking upright guards can perform for many years, being replaced only when repeated or major impact has occurred, making them a cost-effective option. Not only do they protect the upright from most types of impact damage, they also act as a visual deterrent to MHE operators. Usually sold in bright yellow colours, the upright guards signal a hazard to drivers whilst they move around the warehouse.

There are also other types of protection systems you can utilise to prolong the life of your racking, which brings us to tip number three:

3. Install racking protection barriers in high-risk zones

The end of racking aisles can be particularly vulnerable areas for racking damage. Warehouse vehicles will often turn tightly down aisles, causing impact to occur. Our next tip to prolong your racking involves installing impact protection barriers in these high-risk zones.

End of aisle barriers absorb and deflect impact, and come in all sorts of styles and materials. Choose the best option for your warehouse depending on the type of vehicles in operation and the type of racking you have. You should also factor in the amount of maintenance that might be required for certain types of barriers. If contact occurs with painted metal barriers, for example, the barriers will require frequent re-painting to ensure they remain highly visible and keeps your warehouse looking clean and tidy.

With your barriers and guards in place, it’s now time for tip number four:

4. Regularly inspect your racking for signs of damage or safety issues

UK guidelines recommend employers conduct regular and annual racking safety inspections. By checking over racking regularly, and reporting damage straightaway, you’re not only meeting these guidelines, but you’re also helping to prolong the life of your racking.

In busy warehouses, frequent little knocks to racking can go unnoticed. Large pallets of stock can also obscure some areas of damage. Ensuring your team routinely checks over your racking for defects means any potential issues can be flagged and action can be taken. This might be to unload the racking bay and carry out urgent repair work, which leads us into our final tip:

5. Repair damage to racking quickly to reduce serious consequences

The level of damage to racking uprights, bracing or beams is often categorised as a traffic light system by SEMA. Green signals that the damage should be monitored but no immediate action is required. Amber risk signals a hazard that requires action as soon as possible. Damaged categorised as a red risk requires immediate action as the damage is considered very serious.

The level of damage will prioritise which repair work needs to be carried out first. Staying on top of repair and maintenance work will help reduce repair bills long-term as some green or amber hazards may develop into red risk hazards, which are more costly than smaller repairs. Ignoring repair work won’t make the damage go away. Make sure you’re taking all the steps to prevent catastrophic accidents involving collapsed racking, and prolong your racking for as long as possible.