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The fast-paced nature of a warehouse can make it challenging to notice problems with racking systems. But as the first line of defense in preventing severe accidents and delays, everyone has an obligation to stay alert. While a minor dent or bend may seem like nothing, it can quickly develop into a critical safety issue, an extreme violation of protocols and a costly problem to resolve.
Even warehouse environments with the strictest of safety maintenance rules will need racking system upgrades at some point. Knowing when your current racking systems can’t support the production needs of your warehouse is vital.
But how will people know when it’s time to take action? This is where regular warehouse racking inspection can help. Here are the top five signs your warehouse racking system needs an inspection or upgrade.
Noticeable pallet rack damage is easily ignored in a busy warehouse, but visible signs of damage should be an immediate priority. While cosmetic issues like mild scratches can be caused by general day-to-day warehouse activities, other forms of rack damage will require further action, including:
These issues can’t be ignored and should be addressed as soon as possible. Visible damage like this can lead to complete rack collapse, loss of inventory, severe production delays and possible injury.
A sagging beam is a clear sign of structural failure in your warehouse racking systems. It’s usually the result of overloaded beams that have exceeded capacity, or exposure to extreme heat. Some sagging, or deflection, is expected in a loaded beam. However, there are limits to what’s considered a “safe” amount of sagging by the American National Standards Institute (ANSI), which also covers North America.
Dividing the span, or horizontal length, of the beam by 180 gives you the recommended standard maximum amount of deflection permitted. If you notice a sagging beam during an industrial shelving inspection that exceeds this limit, immediately but safely remove the items on the sagging rack and isolate the area.
Under no circumstances should a beam be “bent back” into shape, as it will need to be checked by a qualified professional.
A lot of consideration and planning should go into switching up inventory or big changes in pallet types. Warehouse operations rarely stop, but using a less uniform pallet should be cause for stopping and thinking about how this has affected the work environment.
By changing up the pallet weights, beam elevations or double-stacking pallets in a warehouse, you’re invalidating the engineered drawings and load capacity ratings of the previous system. In Ontario, you are legally obligated to have a pre-start health and safety review (PSR) on your pallet racking system to ensure regulatory compliance.
Therefore, any changes to the racking configuration in your warehouse will need the support of a structural engineer.
Simple but regular pallet racking care can help managers and employees spot hazardous issues as soon as possible. Monthly internal checks and warehouse rack maintenance support a “safety first” culture where every member of your team understands the importance of adhering to a clear maintenance schedule.
Monthly routine warehouse rack maintenance offers many benefits, including:
Skipping these small checks can also void potential insurance policies and warranties. Additionally, ignoring regular maintenance may lead to a more difficult annual warehouse racking inspection by a professional, which is required under Ontario’s Occupational Health and Safety Act (OHSA).
Forklift drivers are the beating heart of a streamlined warehouse. Increased reports of impact incidents from forklift drivers may be a sign that it’s time for some racking system upgrades. It’s important to explore why your drivers have been experiencing difficulties maneuvering around tight warehouse storage areas. Doing so can help you understand why your current racking system is no longer effective.
The reason for this issue may be anything from poorly planned logistics to the size of modern forklifts, which are large and take up more space when transporting and shelving goods. Either way, it indicates a need to assess your warehouse environment and install some robust protection products or consider racking system upgrades.
There’s no such thing as a minor issue when it comes to potential safety risks in the workplace. Improper warehouse rack maintenance can cause significant injuries to your employees. It also influences a poor workplace culture where safety isn’t a priority. This can lead to further problems down the line, and potential production delays due to issues that could’ve been easily resolved if spotted earlier.
Employers also have a responsibility to create a safe place for people to work. In addition to being a moral obligation to your hardworking team members, it’s also another legal requirement that falls under the OHSA.
Knowing which signs to be aware of can influence better safety practices, streamline workflows and reduce the financial pressures of a full-scale racking replacement due to missed issues. By being prepared and having a proactive approach to warehouse storage systems, you can maximize safety without sacrificing efficiency and compliance.
Arbon Canada is dedicated to improving the safety and efficiency needs of our clients’ warehouse spaces. We provide support and assistance for warehouse racking and industrial shelving inspections, PSRs and repairs. Our skilled team members are available to discuss racking system upgrades and other safety hazard prevention requirements.
Have you noticed one of our five signs your warehouse racking system needs an inspection or upgrade? Contact us today for a free facility evaluation.
