Racking installations

Categorised as requiring surveillance only.

• Does not require a reduction in the rack carrying capacity or immediate repair
• Considered safe and serviceable
• Should be clearly identified for specific re-examination at future inspections
• Exceeding this level should be considered a risk to the racking system

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

Categorised as very serious damage requiring immediate action.

• Situations where a critical level of damage is identified
• The racking should be immediately offloaded
• The racking should be isolated from future use until repair work is carried out
• Repair work usually involves replacement of the damaged component

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.

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.

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.

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.

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.

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.

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.

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.

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.

PALLET SAFETY GATES

FEATURES: Safely load and unload pallets from mezzanine floors. Multiple options to suit requirements.

IDEAL FOR: Mezzanine floors, new installations or retro-fitting to existing structures.

MEZZANINE FLOORS

FEATURES: Increase available storage area without expanding warehouse floor space.

IDEAL FOR: Additional racking or shelving, office spaces and meeting rooms, canteens.

SHELVING SYSTEMS

FEATURES: Multiple options available, flexible and adaptable storage for all types of use.

IDEAL FOR: Stand alone shelving, high-rise installations, multi-tier systems, manual or automated picking.

MULTI-TIER RACKING

FEATURES: Pallet racking structure with multiple levels and walkways. Can be installed from the floor or on mezzanine structures.

IDEAL FOR: Multi-functional, manual storage, cartons, boxes, garment storage.

LONGSPAN RACKING

FEATURES: Versatile and adaptable storage for warehouse and office environments. System accessible from both sides.

IDEAL FOR: Small and large items, industrial storage, archive storage, commercial stores.

CANTILEVER RACKING

FEATURES: Versatile storage for long, heavy goods. All levels accessible by forklifts, Light, medium, or heavy duty.

IDEAL FOR: Horizontal storage of long items such metal bars, pipes, tubes, or timber.

PUSH BACK RACKING

FEATURES: Single aisle loading for compact and efficient storage. LIFO (Last In, First Out) system goods are pushed back by the next one.

IDEAL FOR: Loading and unloading from the same side, non-perishable goods.

PALLET FLOW / LIVE RACKING

FEATURES: Inclined roller beds enable pallets to move along to the end of the level. FIFO (First In, First Out) for efficient loading / unloading.

IDEAL FOR: Stock with best-before dates, food, medical, or cosmetic products.

DRIVE-IN RACKING

FEATURES: Compact, high density storage that reduces forklift operations and maximises space and height.

IDEAL FOR: Large quantities of identical goods, goods with low rotation, non-perishable items, LIFO (Last In, First Out) operations.

MOBILE RACKING

FEATURES: Dynamic and high-density storage. Direct access to any stored pallet.

IDEAL FOR: Warehouses that need to optimise space, cold or freezer storage, and those with low turnover goods.

DOUBLE DEEP RACKING

FEATURES: High storage density for reduced number of aisles. Adjustable and efficient storage for LIFO (Last In, First Out) use.

IDEAL FOR: Warehouses with non-perishable, duplicate stock items.

SHUTTLE RACKING

FEATURES: Compact, high-density storage. Optimum use of space with semi-automated FIFO (First In, First Out) or LIFO (Last In, First Out) options.

IDEAL FOR: Warehouses with high turnover of stock, high volumes of pallets, seasonal merchandise, cold and freezer storage, perishable and non-perishable stock.

NARROW AISLE RACKING

FEATURES: High density system for efficient storage. Flexible and compact, special handling equipment is required.

IDEAL FOR: Warehouses with reduced floor space, those needing quick access to loads, or items in high rotation.

WIDE AISLE RACKING

FEATURES: Unrestricted access to pallets at all times. Versatile and long lasting.

IDEAL FOR: Warehouses storing pallets, containers, or individual boxes.

ADJUSTABLE PALLET RACKING (APR)

FEATURES: Efficient and robust systems for heavy loads. Palletised items accessible by forklift trucks.

IDEAL FOR: Warehouses storing pallets, containers, or individual boxes.