racking safety audit report -cscl

Racking Safety Audit Report

Prepared by

Julian Kalac, P.Eng.

6/19/2013

of 12 CSLC Racking Safety Audit Report 19 June 2013

To: Grant Donnelly, Chris Hawrelak, Bob Bloomer C.C.: Winston Shim, George Asamoah

From: Julian Kalac, P.Eng License #90505462

Date: June 19, 2013

Re: Safety Audit Report

Overview:

I am a Mechanical Engineer and a Professional Engineer (P.Eng.) with over 16 years working in the

manufacturing industry with industrial machines/equipment. My experience and training have

made me very familiar with OSHA regulations and standards.

Objective

The objective of this report is to provide an initial assessment of the Pallet Racking Safety

conditions and recommend improvement suggestions that ensure full compliance to OHSA

standards and regulations.

Referenced Standards

CSA A344.1-05 User Guide for Steel Storage Racks

CSA A344.2-05 Standard for the Design and Construction of Steel Storage Racks

ANSI/ALI ALOIM-2000---Safety Requirements for Operation,

Inspection/Maintenance

Regulation 851-Industrial Establishments

Regulation 851 was developed to address the issues specific to all industrial

establishments such as factories, offices, arenas, or shops operating within Ontario. It is

for this reason that Regulation 851 covers a broad range of requirements on topics such

as industrial hygiene, machine guarding, fire prevention, confined spaces, equipment

maintenance, material handling, and protective equipment.


Certain Sections of Regulation 851 require the preparation of a written report to provide a

permanent record regarding the occurrence of health & safety issues. In particular,

Section 7 requires preparation of a written report detailing the measures that must be

taken for compliance with the relevant provisions listed in the Table

There are 5 steps in completing a Pre-Start Health & Safety Review (PSHR)

1. Safety Audit / Risk Assessment

2. PSR (Pre –Start Safety Review)

3. Design And Installation

4. PSR Sign-Off …

5. Training and Documentation

In House Racking

The pallet racks used in the warehouse are used and have been modified from it’s original

design. No PSHR was ever conducted. The main concern is the lack of documented load

rating capacity for the racks as well as several safety violations and hazards which are

shown in the pictures taken.

I was told by the only material handler who uses the rack that the load rating is 9000

Lbs/beam, which is highly unlikely given the 1/8” thickness of the cross section and

¾” Beam Depth.

No supporting documentation was provided. Therefore if no documented load ratings are

available, a PSHR must be conducted. (see MOL flow chart on Racking PSHR)

¾”

1/8”

”

http://www.jecinc.on.ca/pshsr-act.shtml#protable


PHSR Regulation 851, section 7

Applicable provisions

of Regulation 851 Circumstances

1. Subsections 22 (1), (2) and (4) Flammable liquids are located or dispensed in a building, room

or area.

2. Sections 24, 25, 26, 28, 31 and 32 If any of the following are used as protective elements in

connection with an apparatus:

1. Safeguarding devices that signal the apparatus to stop,

including but not limited to safety light curtains and

screens, area scanning safeguarding systems, radio

frequency systems and capacitance safeguarding

systems, safety mat systems, two-hand control systems,

two-hand tripping systems and single or multiple beam

systems.

2. The barrier guards use interlocking mechanical or

electrical safeguarding devices.

3. Clause 45 (b) Material, articles or things are placed or stored on a structure

that is a rack or stacking structure.

4. Section 63 A process involves a risk of ignition or explosion that creates a

condition of imminent hazard to a person's health or safety.

5. Section 65 The use of a dust collector involves a risk of ignition or

explosion that creates a condition of imminent hazard to a

person's health or safety.

6. Sections 87.3, 87.4, 87.5 and 88,

subsections 90 (1), (2) and (3), and

sections 91, 92, 94, 95,

A factory produces aluminum or steel or is a foundry that melts

material or handles molten material.

7. Sections 51 and 53 The construction, addition, installation or modification that

relates to a lifting device, traveling crane or automobile hoist.

8. Sections 127 and 128 This process uses or produces a substance that may result in

the exposure of a worker in excess of any occupational

exposure limits as set out in Regulation 833, 835, 836, 837, 838,

839, 840, 841, 842, 843, 844, 845 or 846 of the Revised

Regulations of Ontario, 1990.


Issue #1 –Beam Connectors damaged due to overloaded

(double stacked)pallets

Large amount of deflection indicates overloading of the racking. Where two beams

connect at an upright, the beam connectors should be parallel.

If racking is or has been overloaded, the beam connectors may be deformed

There will also be evidence of ‘permanent set’ in unloaded beams.

Above pictures shows 6 double stacked skids ~6000Lbs sitting on racking beam

which can only hold Max 1500Lbs, causing damage and deflection

6 DOUBLE STACKED SKIDS = 6000Lbs on damaged rack beam which can hold Max 1500Lbs


ISSUE # 2 NO SIDE GUIDE

RAILS CREATING HIGH RISK OF TIPPING/FALLING DOWN. CRITICAL INJURY!!


Locking Pins/keys are inserted into the racking to prevent the unit load from

being dislodged unless mesh decks or other form of support structure has

been designed and fitted.

Missing Locking Pins

ISSUE # 3 OVERHANGING SKID CRUSHING INJURY

NO SAFETY PINS

No Cross Bars


SKID ALMOST OFF

THE RACK CRITICAL INJURY

SHIFTED LOAD –CRUSHING INJURY


MOL GUIDELINE FOR PSHR—RACKING


Racking Load Capacity


Racking design Information needed for Load Calculations

The Canadian Standards Association has two standards that provide the information you need.

CSA A344.1-05 User Guide for Steel Storage Racks

CSA A344.2-05 Standard for the Design and Construction of Steel Storage Racks

1. What is the Bay Clear Entry?

Single bay racking

In situations where single rows are installed, and there is pedestrian access along the rear of the racking,

rear protection should be installed to prevent loads falling out of the back of the racking.

2. What is the racking beam section?

Open beam or a box beam? The box beam is a heavier duty beam than the open

beam, so this is crucial to the strength of the entire racking system and the

loading it can take.

11

FT

8F

T


3. How big are the racking frames?

It is important to know the dimensions of the racking frames. The measurement

required is the Height (H) (mm) x Width (W) (mm) of the frames.

4. What is the vertical beam pitch of your racking system?

The height of each storage level, measured from the floor to the top side of each

beam. If the number of beam levels varies across the racking system, then the

load criteria will also vary.

racking safety audit report -cscl

Health & Medicine

safety requirements

safety audit report

safety violations

safety audit risk assessment

racking pshr

safety light curtains

written report

phsr regulation