Whether it’s a case of building a new facility, or expanding or modifying an existing one, safety measures to guard personnel should be an essential part of the planning. The needs will differ in each facility. If implemented correctly, a safe and economical environment will result and greater productivity will be the reward.
The majority of warehouses display major problems regarding storage safety. Broadly, the typical problems include:
Pushing pallets to line up with front face:
Many operations push the pallet into the rack so the pallet lines up with the front rack beam. This causes major safety problems as the back beam and back portion of the frame are overloaded, sometimes by up to 40 percent; the pallet is supported on the back beam in the wrong place, mainly not under the bearer; and the fire clearance (back to back) is closed, so preventing effectiveness of sprinklers. Proper guarding should be fitted to the rear of a pallet rack to prevent goods from falling out and causing injury to personnel and damage to goods.
Rack the wrong depth for pallet:
Many rack installations are the incorrect depth for the pallet stored. Pallets must be stored under the support bearers. Typically, a 1 000 mm deep pallet requires a frame depth of 900 mm. A 1 200 mm deep pallet requires a frame depth of 1 100 mm.
Rack damaged:
Racks are supported by frames that could be damaged. Even a slight dent could result in the carrying capacity being significantly reduced. Loading a damaged rack could result in collapse and injury to staff.
Rack badly designed:
The racking industry is highly competitive and many suppliers are cost competitive because they design very close to the operational limits with small safety factors. Even the slightest change from the original designed use can cause major downstream problems. Caution must be exercised and when in doubt consult a professional engineer. Always buy from the person who has the better rack, not the cheapest rack. Examine existing systems.
Second-hand racking:
One of the most dangerous practices is to use second¬hand rack – especially if its previous application is unknown. Furthermore, when re-using rack, it will be for a totally different application with different forces from what it was designed for originally. The SA specifications call for a 40 percent de-rating of rack when using second-hand rack. Very few organisations comply with these recommendations.
Rack protection:
Heavy-duty applications require matched rack protection. This will reduce damage and ensure operational safety. Use correct handling equipment with appropriate turning circles and efficient access.
Fire prevention and control:
The worst-case scenario for any warehouse operator must be an out-of-control fire raging unchecked through the facility.
Two over-riding controls ensure that most of today’s newer facilities have built-in preventative measures and counteractive mechanisms to prevent and control fire risks: the first is comprehensive legislation that governs the mechanisms and ensures the safety of the workers involved, and the second is the insistence of insurance companies that all prevention and safety measures are in place.
These requirements are not infallible – witness the razing over the past few years of a number of warehouses of reputable companies.
There are many factors that must be taken into account:
• Each type of business deals in commodities that have their own weaknesses
• The packaging can present a risk factor in its own right and can present a major threat
• Each environment has its own overall risk factors
• The type of racking is a contributing factor
• Design factors, such as the height of the facility and availability of water, can contribute to the risk as well
Typical considerations must include fire detection systems; immediate fire fighting equipment like extinguishers and hoses; automatic fire extinguishing systems such as sprinklers; and fire separation systems such as firewalls and building section separators.
When installing rack in a warehouse make sure it is properly designed and built for the job; it complies with local and international standards; it is safe; it is not damaged; it is compatible with the pallets being used; it is used correctly; and it is properly maintained. Safety in the workplace demands co-operation and alertness on everyone’s part. Supervisors, operators, pickers, packers and other workers who notice hazards in need of safeguarding, or existing systems that need repair or improvement, should be trained to notify the proper authority immediately.