RATED CAPACITY
There are two critical rated capacities related to racking and they should never be exceeded.
They are:
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maximum unit load
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total rated capacity for each bay
Unit load is an individual stored item – eg a pallet having material that can be placed or retrieved in one operation.
Total weight of unit loads stored on a bay must not exceed the rated capacity of the bay.
This information should be provided to people who use the racks. One of the most effective means of providing this information is to mark it clearly in a visible location on the racking.
The racking supplier should provide the following:
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racking manufacturer’s name, supplier’s name and trademark, and the installation date
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designer’s name (company or individual)
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working unit load limit
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total working unit load limit for each pallet beam level
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total working unit load limit for each bay
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maximum distance from the base plate level to the first beam level and maximum distance between adjacent beam levels
There should always be some way of determining the weight of each unit load being placed into the racking. See figure 1 for an example of safe working loads.
Figure 1: A typical safe working load sign.
Note: Changes to the racking configuration alters the safe working loads. Obtain prior approval from supplier.
Note: Rated capacity in this case is based to a unit load of 1200kg on a standard pallet. For uneven loads where a large load is only supported at two or three points, refer to the supplier to determine whether the racking is capable of supporting that load.
PALLET RACKING FACTS
RACKING DESIGN AND LAYOUT
Any racking used in the workplace should be designed specifically for the size, shape and weight of the products being stored. It is also important that all racking is set up and maintained according to the manufacturers’ instructions.
The layout of racking should be compatible with the material handling equipment used in the workplace – eg aisle width should match the turning circle of the forklift used for picking and replenishment.
The layout should also consider emergency access, adequate lighting and any manual handling activities.
MODIFICATIONS TO RACKING DESIGN OR COMPONENTS
Modifications should only be made by a competent person who has been given all the information provided by the supplier.
Any modifications to the racking should take into account the effect on load limits and should also be approved by the manufacturer, supplier or a qualified engineer who has knowledge and experience in similar work. Operating procedures, signs and drawings must be updated to include details of the modification.
Never make physical alterations to uprights, bracings, beams or components – eg welding on additional cleats or bearers without the approval of a competent person.
Replacement of uprights, bracings, beams, clips or other components should be done using parts from the equipment manufacturer. If alternative parts must be used, an engineering report should confirm that they are compatible with racking being repaired.
OPERATING INSTRUCTIONS
Put procedures in place to ensure operations are done safely with regard to the racking design, the load and capability of lifting equipment (see figure 2).
As a minimum, these should include:
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correct use of the handling equipment
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rated capacities of the racking
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prohibitions on unauthorised alterations
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a clear process for reporting any damage as soon as it occurs
REPORTING UNSAFE SITUATIONS AND DAMAGE
All safety risks related to operation or maintenance of the racking should be reported to management immediately. In some circumstances – eg major collapse of racking exposing a worker or others to serious health and safety risks, WorkCover must be notified immediately by calling 13 10 50.
Workers should report any damage to a supervisor immediately so it can be inspected and assessed.
Damage should be recorded – eg coloured stick-on tags used to show the location and level of damage. See figure 3.
