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Rust and Corrosion

Rust and corrosion can seriously weaken racking

Key things to know:

Rust and corrosion weakens racking components, compromising the safety
All steel will eventually corrode over time
Racking typically rusts when exposed to moisture for long periods
Paint or rubber coatings can help slow down corrosion, but can also mask issues as well as requiring maintenance

REPAIR: Monitor cases of rust and corrosion, replacing all components that pose a safety risk.

PREVENT: Store components inside and away from moisture. Choose racking made from galvanised or stainless steel to slow down any corrosion.

Missing or Damaged Weight Load Notices

All racking is required to have a Safe Working Load Sign

Key things to know:

The safe working load limit of the rack needs to be displayed clearly for colleagues to see
The signs should be mechanically fitted in a conspicuous location 2m from the floor
They should be made from corrosion-resistant material
Every sign should include: the suppliers name, safe working loads, height to first beam, and beam pitch

REPAIR: Replace damaged Weight Load Signs or order replacement signs if your storage system has been altered since installation. Need help calculating your safe weight load? We can help.

PREVENT: Ensure all aisles of racking have Weight Load Signs to avoid beams becoming overloaded and unsafe.

Beam End Connector Damage

Beam end connectors are prone to knocks and tears

Key things to know:

Beam end connectors should show no signs of cracking
If there are any signs of deflections, unload the beam and seek advice from your racking supplier
Attempting repairs by untrained staff can compromise the load capacity of the beam and safety of the entire rack

REPAIR: Damaged beam end connectors often result in a replacement of the entire beam to preserve the safety of the racking system.

PREVENT: Regular inspections of the system, professional repairs, and skilled operators can all help reduce the risk of beam end connector damage.

Beam Damage & Repair

Beams can be hit when loading pallets and MHE turning in aisles

Key things to know:

Damage most frequently occurs on the first level
Unstable beams result in unsecure pallet loads, creating a safety issue
Beams have a deflection tolerance when loaded that should disappear when unloaded
Deflections showing when unloaded should be within the safe limit for that beam

REPAIR: Replace damaged beams above a category green risk to ensure your racking is safe and operational.

PREVENT: Ensure the correct beam is being used for your storage needs and regular training is given to operators to reduce the number of beam impacts.

Bracing Damage & Repair

Bracing and frames can be hit by moving pallets or MHE.

Key things to know:

Bracing can become torn or bent, compromising the load capacity of the racking
Damage can reduce the capacity of the frames to withstand accidental frontal impact
Deflections should be no more than 10mm in either direction before needing repair
Deflections under 10mm should still be monitored and reassessed at the next inspection

REPAIR: Replace or repair damaged bracing as soon as is required of the SEMA code of practice.

PREVENT: Although sometimes unavoidable, protecting racking frames with impact protection barriers can help reduce how close MHE can get to the racking. Training operators on careful and accurate placement of pallets can also help prevent damage.

Missing Anti-Collapse Mesh

Anti-Collapse Mesh prevents accidents from falling objects

Key things to know:

Single-sided runs of racking should have mesh installed to prevent items being pushed or falling off the other side
Mesh is especially important if the run of racking is next to pedestrian routes
Anti-Collapse Mesh can be installed on existing racking

REPAIR: Request anti-collapse mesh to be installed on any existing racking systems that require a barrier between operatives and stored items.

PREVENT: Add anti-collapse mesh to racking when installed to ensure the racking is safe before use.

Dislodging and Missing Bolts

Missing bolts and locking pins can result in dislodged components

Key things to know:

FEM recommends all racks are fixed to the floor with at least 1 bolt per base plate
Beam safety locks, or locking pins, provide resistance against accidental beam dislodgement
There should be 2 safety locks per beam
Dislodged beams result in unstable pallet loads and an increased risk of falling from height
Each racking type has a compatible locking pin, do not use nuts and bolts to secure beams to uprights

REPAIR: Order replacement bolts and safety locks. Replace any damaged beams that have become dislodged and require repair.

PREVENT: Regular inspections should include checking for any missing bolts / locks, as well as any dislodgement of beams. Hold stock of safety locks to replace any missing components.

Base Plate Damage & Repair

Base plates are essential components for the safety of racking

Key things to know:

All racking should be fixed to the floor using 1 or more bolts per base plate
Unsecured racking is more vulnerable to collapse from impact
Damage to base plates can often cause damage to the floor

REPAIR: Damaged base plates should be repaired or replaced as soon as they pose a safety risk.

PREVENT: Ensure all base plates are secured to an unbroken floor with at least 1 bolt. Protect MHE from hitting uprights and base plates with racking protection guards.

Upright Damage & Repair

Racking front and rear uprights are often impacted by MHE.

Key things to know:

Bends or twists can compromise the load capacity of the whole racking system
Deflections forwards or backwards should be no more than 3mm before needing repair
Deflections sideways should be no more than 5mm before needing repair
Repairing uprights by welding replacement sections compromises the safety of the system

REPAIR: It’s advised that damaged racking uprights are replaced rather than repaired to ensure safety compliance.

PREVENT: Most damage occurs within the first 600mm of the upright. Protect racking uprights from being damaged in the first place. Protection guards deflect and absorb impact before it can cause damage to the upright.

What is red risk damage?

What is amber risk damage?

Categorised as hazardous damage requiring action as soon as possible.

Area where damage is significant to warrant redial work, but doesn’t require immediate offloading
Once load is removed from a damaged component, it should not be reloaded until repairs have been carried out
Isolate the rack following offloading to prevent use until repair work is carried out
Repair work should be carried out within 4 weeks, otherwise the damage is re-categorised as red risk and immediate action is required

What is green risk damage?

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