cop rack safety inspections v1 4

of 20 Version 1.4 issued 10/07/13

Code of Practice For

Rack Safety inspections

Australian Steel Storage Manufacturers Group

(ASSMG)


Foreword This Code of practice on how to manage Rack safety inspections is produced by the

Australian Steel Storage Manufacturers group (ASSMG)

The main objective of the COP is to standardise rack inspections across the whole racking

industry within Australia, and to raise the standard of the inspection and reporting process.

By adopting best practices that the industry offers, will help minimise the potential risk of

injury to personnel, damage to goods & interruption of business.


Contents

CONTENTS ........................................................................................................................................................... 3 TERMINOLOGY .................................................................................................................................................. 4 PURPOSE OF INSPECTIONS ............................................................................................................................ 5 INSPECTIONS ........................................................................................................................................................ 5 DAMAGE CONTROL PROCEDURES ................................................................................................................. 5 DAMAGE EVALUATION ..................................................................................................................................... 5 DAMAGE ACTION FLOW CHART ..................................................................................................................... 6 ASSESSMENT OF UPRIGHTS AND BRACING ............................................................................................. 8 RACKING INSPECTOR SAFETY ..................................................................................................................... 9 RACKING INSPECTOR PROTOCOL .............................................................................................................. 9 RACKING INSPECTOR TOOL LIST ............................................................................................................. 10 INSPECTION PROCESS ................................................................................................................................... 10 OUT-OF-PLUMB RACKING ............................................................................................................................ 12 OTHER TYPES OF DAMAGE AND CONSIDERATIONS .......................................................................... 15 APPENDIX ........................................................................................................................................................... 19

RACK INSPECTOR QUALIFICATIONS .................................................................................................... 19


Terminology

Competent person A person who has acquired through training, qualification or experience, or a combination of both the knowledge and skills required to safely carry out a task.


Purpose of Inspections It is recommended that a system of regular inspections for pallet racking installations shall

be carried out on a regular basis and at least once every 12 months, in accordance with

AS4084:2012 (Ref.As:4084, Inspections, page 100)

(a) ensure the correct application and use of equipment

(b) ensure that the working load limits are adhered to

(c) ensure that the racking installation has not been altered

(d) Examine the extent of damage due to impact on the racking installation

(e) Examine the out of plumb of the racking

(f) Examine for any dislocation and deformation of sections and connections for uprights

and beams

(g) Examine connectors for deformation or signs of cracking at the welds

(h) Examine base plate for anchors

Inspections Yearly or half yearly formal inspections must be carried out by a competent person, fully

experienced in the identification and categorisation of racking damage. (Ref appendix 1,

Rack inspector qualifications)

Damage control procedures An inspection report of rack damage should initiate a management procedure for isolating

and making safe, sections of seriously damaged racking.

The inspection report should contain observations and proposals for any action necessary,

with recommendations to reduce or eliminate the problem of damage reoccurring again.

Damage evaluation The seriousness of structural damage to uprights, bracing members, beams or base plates

should be evaluated, classified and recorded systematically.


Damage action flow chart

Green Risk

When the level of damage does not exceed the permissible limits specified in Fig.1 the

racking shall be considered serviceable and does not require either unit load reduction or

immediate unloading,

Damaged components shall be recorded as suitable for further service until the next

inspection and shall be clearly identified (stick on labels) for specific re-examination and

assessment at future assessments.

NOTE: Exceeding the green level shall be considered hazardous or very serious damage to

the racking system.


Amber Risk

When the level of damage exceeds the permissible limits specified in Fig.1 by up to a factor

of 2, the damaged section shall be clearly marked and isolated until remedial work has been

carried out before the racking can be reloaded.

If remedial work can not be carried out within 4 weeks, the level of damage shall be

redesignated as ‘very serious damage’ (red risk)

Red Risk

When the level of damage is in excess of the permissible limits in Fig.1

By more than a factor of 2, the damaged section and appropriate adjacent section(s) shall be

immediately unloaded and isolated from further use until remedial work has been carried out

and certified as safe.

Any repair works shall be in consultation with the racking supplier or a qualified structural

engineer.

NOTE: Only like for like materials must be used when repairing a damaged rack.

Damaged components must be replaced with new or good quality undamaged second hand

product, but not reworked or copy products.


Assessment of uprights and bracing Where practicable place a 1000mm straight edge on the face of the damaged member,

keeping the damaged area as close as possible to the centre of the straight edge, then

measure the indentation.

Note: Where practicable always test over a 1000mm span.

Fig. 1

• For an upright bent in the direction of the rack beam spans, the maximum gap

between gap between the upright and the straight edge should not exceed 5mm.

• For an upright bent in the direction of the frame bracing, the maximum gap between

the upright and the straight edge should not exceed 3mm.

• For an upright that is damaged such that there is damage in both longitudinal and

lateral directions, the left-to-right and front-to-back deformation shall be measured

and treated separately and the appropriate 5mm and 3mm limits observed.

• For bracing members bent in either plane, the gap between the straight edge and the

bracing member should not exceed 10mm.

• Other items that may cause concern:

Splits, tears, deformation or collapsed upright sections.


Racking inspector safety

Safety of the rack inspector is paramount to a successful inspection/audit.

• Where a customer doesn’t have suitable procedures for personnel interaction and

material handling equipment (MHE), a JSA/SWMS must be written, prior to starting

the inspection.

• Where practicable the aisles are to be barricaded or bunted off to prevent MHE from

entering, or as a minimum signage or safety cones must be positioned at the ends of

the working aisle.

• If barricades and bunting are unacceptable to the customer, it is mandatory for the

inspector to request that ALL operators within the facility are advised of the presence

of inspectors within the warehouse, especially as there may not be designated

walkways, separating pedestrians from MHE.

• Inspectors must be trained in warehouse safety and must be alert at all times to the

potential dangers within the warehouse, especially advancing with caution when

entering or leaving an aisle.

• High visibility vests must be worn at all times, having reflective tape front and back,

both horizontally and vertically. A hard hat & safety shoes, should also be mandatory

PPE

• Freezer rooms pose a different hazard to a standard warehouse, therefore prior to

starting the inspector must always negotiate the safest and most acceptable method

possible, to carry out the inspection. Wearing a freezer suit or appropriate warm

clothing is mandatory for all inspectors working in a freezer environment.

Mobile telephone should be turned off.

Racking inspector protocol

• Always contact the client on arrival and on completion of the inspection, advising the

client of any Red damage

• Sign in & out of the site (if appropriate)

• Attend a site induction if appropriate

• Always follow the site specific safety rules.

• Always follow and maintain the racking inspector’s safety protocol.


Racking inspector tool list

• 1Mtr long spirit level or straight edge

• Laser measure

• Tape measure

• Digital camera

• PDA or tablet/I pad (if appropriate)

• Torch

• Clipboard

• Working pen & pencil

• Appropriate paperwork required for the inspection

Inspection process


Assessment of beams- Vertical deflection Beam span

In measuring vertical beam deflection comparison measurements must be made between

straight level edges e.g. a second beam level set below the suspect beam.

To take a measurement the comparison beam and the suspect beam must be unloaded.

Three vertical measurements should be taken from the centre and two outer edges of the

suspect beam, the difference being the permanent deflection.

NOTE: The maximum permanent vertical beam deflection in an unloaded condition = 20% of

loaded deflection.

Horizontal beam deflection The maximum permanent horizontal beam deflection in an unloaded condition

= 50% of tolerance deflection. (Refer table 1.7.1 page 13)


Out-of-plumb racking Out-of-plumb racking poses a risk that could eventually lead to rack failure.

Any visible signs of out-of-plumb or signs of the rack leaning must be investigated

immediately.

The causes of out-of-plumb racking can be;

• Damage from impact

• Incorrectly installed

• Component failure

• Excessive loads

• Concrete floor sinking

To comply with AS: 4084-2012 pallet racking is to be installed to meet finished tolerances

as specified in section 7.

Out-of-plumb tolerances are tabled below (Ref AS: 4084-2012)


(Ref AS: 4084-2012)


Ref AS: 4084-2012


Other types of damage and considerations Load signs

AS: 4084-2012 states that the racking installation shall have, in one or more conspicuous

locations, a permanent, corrosive resistant plaque, not less than 125mm long and 250mm

high, mechanically secured to the racking structure at 2mtr above the floor level.

A typical load sign should contain but not limited to:

1. Racking manufacturers name, suppliers name and trademark

2. Designers name

3. Working unit load limit

4. Total working unit load limit for each pallet beam level

5. Total working unit load limit for each bay

6. Maximum distance from the base plate, to the first beam level and maximum

distance between first and second beam levels

7. Installation date

8. Clients name

Typical racking SWL sign

3

4

5

6

2

1

8

7


BEAMS

• All beams are fitted with safety clips.

• All connectors are correctly installed in the uprights (no dislodgement).

• No visible deformity of the beam (if this not evident in loaded situation – the beams

should be unloaded and checked).

• Rotation of the beam

• Sign of cracks in the welds

• Sign of bowing or bending on beam end connector

• Sign of corrosion.

• Impact damage to beams.

• Sign of separation of the welded sections.

• Check if the levels correspond to the SWL signage

Base plates

• Visible damage to the base plate.

• Damaged floor fixings.

• Base plate is secured to frame correctly.

• For selective pallet racking to conform to AS: 4084-2012, there must be 2 anchors

securing the base plate to the concrete slab.

Installations prior to the 2012 standard may only have 1 fixing.

Duel fixings to front corners

Or diagonally fix

Loose, missing or dislodged racking components

Loose, missing or dislodged racking components can cause major immediate risks with the

structural integrity of the racking.


Frames

• All uprights are fixed to floor using the correct type floor anchors, for the application

(2 floor anchors /base plate required if installed after 28/2/2012 ref AS: 4084 2012).

• Signs of visible damage to the upright sections.

e.g. twisting of the upright; any sign of any tears or significant dents in the uprights –

the frame should be unloaded and not put back into use until repairs have been

completed

• Signs of visible damage to the bracing sections.

• Rack protection is installed and is in a good state of repair.

Corrosion

Severely corroded components can fail without warning. At the first sign of corrosion an

investigation should be carried out to determine the cause of the corrosion.

Thin walled boxed beams could develop corrosion from the inside, and it may take

considerable time before showing signs of any corrosive damage. A collapse could occur

before showing signs of corrosion, therefore special care and consideration should be taken

when assessing the risk. As a guide, blistering on the surface will indicate excessive

corrosion is taking place internally.

Pallets

Pallets often get overlooked in the rack inspection process; however pallets can cause

damage to the structure or mobile plant and cause serious injury to persons working in the

vicinity.

• Pallet should be designed for the racking and lock into position (Australian Standard

Pallet – CHEP type).

• All pallets should have front to rear bearers capable of supporting the loaded

pallet – other styles of pallets require additional support (refer customer to

manufacturer).

• Broken pallets should be removed from the racking – possibility of collapse.

• Oversized pallets should not be stored in a rack unless the rack has been designed

for the pallet.

• Oversized pallets should not be stored in a standard double entry rack –

possibility of interaction of pallets at the rear of the rack.

• Undersized pallets should not be stored in pallet racking – possibility that they can

fall through the rack.

• Products should not protrude beyond the pallet unless the rack has been designed


for this situation.

• Loose product stored on upper pallet levels should be secured to the pallet

(strapped or wrapped as required) to prevent items falling from height.

• Plastic pallets should not be used unless there is a locking mechanism to prevent

the pallets sliding on the beams.


Appendix RACK INSPECTOR QUALIFICATIONS

ASSMG have set minimum qualifications for rack inspectors. The following minimum

requirements of EXPERIENCE and EDUCATION are a pre-requisite for applicants prior

to being considered for further ‘on the job’ training.

1. EXPERIENCE (proof of evidence must be provided)

Applicants shall have minimum of 5 years full time experience working in the

role of DESIGNER, ENGINEER, MANUFACTURER or INSTALLER of pallet

racking systems.

OR

Applicants shall have a minimum of 5 years full time experience in the role of

Occupational, Health or Safety Manager or in a senior management role

ultimately responsible for employee safety.

2. EDUCATION (proof of successful completion required)

Applicants shall have a minimum level of education qualification as stated below

a) Certificate IV in OHS

3. KNOWLEDGE

Applicants shall have read and understood the following publications (proof of

knowledge during ‘on the job’ training)

a) Duty of Care provisions for each state authority

b) AS4084-2012, Sections 1.6, 1.7, 6.4, 6.5, 6.6 and 8

c) BCA access/egress requirements

d) ASSMG Code of Practice for Rack Safety Inspections

e) Company Operator/User manuals

f) Company Rack Inspection manuals

Approval may be granted to complete educational qualifications during ‘On the Job’ training

however certificates of completion cannot be issued until all qualifications are met.


‘ON THE JOB’ TRAINING

Once the minimum requirements for experience, education and knowledge are met,

further ‘On the Job’ training is required to achieve competency as a qualified rack

inspector.

‘On the Job’ training will be undertaken under the guidance of a senior experienced

rack inspector nominated by the company and will cover the following areas of

competency

a. Damage Identification

b. Damage Assessment and Classification

c. Causes of Damage

d. Damage Reporting and Repairs

e. Customer Service

For application with rack design/installation industry experience a minimum period of 3

months ‘on the job’ training is required before competency can be fully assessed and

certification approved.

For applicants from outside the rack design/installation industry, a minimum of 6 months ‘on

the job’ training is required prior to competency assessment and certification approved.

Further ‘on the job’ training may be required (at the discretion of the trainer) for successful

completion of the training and final certification.

Certification is valid for an initial 2 year period thereafter re-certification will be provided after

a successful audit. Re-certification will also be required should there be any changes to the

standard or alterations to rack inspection criteria by any local or national safety authority.

Failure by qualified rack inspectors to seek re-certification will result in cancellation of the

inspectors’ certification.

An audit will be undertaken of the rack inspectors annually, by ASSMG, and may also be

undertaken should ASSMG be made aware of sub-standard performance of a qualified rack

inspector. Failure to pass an audit will result in the cancellation of the inspectors’

certification.

cop rack safety inspections v1 4

Documents

rack inspections

racking inspector safety

racking industry

racking inspector protocol

purpose of inspections

rack inspector qualifications

types of damage

damage evaluation