Safe shelving

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“This means the suitability is subject to certain specifications. For example, the loads being carried by the racking will contribute either positively or negatively to the system’s structural integrity. If overloading occurs, it can result in accidents.”

The load limits of the entire racking system, as well as each shelf, should be clearly stated to ensure warehouse staff are aware of maximum load sizes. This information should be placed in conspicuous locations, such as at the end of all aisles.

Racking systems are generally produced using lightweight material, which limits their ability to withstand large amounts of wear-and-tear. If the forklifts in the warehouse happen to crash into a racking system, for example, the resulting dents can affect the load-carrying ability of the racks and create a dangerous working environment for employees.

“The racking systems can receive structural damage following a harsh blow,” says Tamari. “Although incidental scrapes are normally quite harmless, anything more serious, like a dent resulting from a forklift collision, means the damaged component will probably need replacing.”

This highlights the importance of careful forklift truck driving within the warehouse. The skill of these drivers has a great bearing on the amount of damage likely to be caused. If the operators are reckless whilst handling vehicles, the chances of mishaps occurring are much higher.

“Damage can be avoided if the company hires good quality forklift truck drivers,” says Wheatley. “If the company notices damage whilst inspecting the racking systems, it must research the cause and discuss the situation with the responsible forklift truck driver. If the damage continues, the company must decide whether to provide some form of training or whether to take action against the driver, such as issuing warnings.”

There are various different types of forklifts available in the market, each suitable for different purposes. It is very important that warehouse operators use the forklift most suitable for the individual task. Using an inappropriate forklift can also cause damage to the racking.

“Sometimes companies are not educated enough in using the right forklifts,” says Tamari. “A reach truck is different to a counter balance forklift. They perform different functions. So if a driver is using the wrong forklift and pushing up instead of pushing down, it can cause the racking to collapse.”

In addition to efficiently driving the right forklift, companies can also purchase optional tools such as steel or plastic protection systems to help prevent damage. Impact damage is most likely to occur at the base of any frame, even more so in the case of the end frames.

The protectors are placed over the front face of a rack upright and even if serious damage occurs, the protector is replaced rather than any component of the racking system, which is a cheaper option.

Purchasing quality racking and conducting regular inspections will bring long-term benefits to companies. Although the safety aspect of warehouse racking is somewhat neglected, the situation is showing signs of improvement.

Of course, no matter how well storage systems are designed and forklift truck drivers trained, damage to warehouse racking systems is inevitable. Luckily, reducing the risk of mishaps is relatively simple, saving money in the long term and ensuring the safety of your warehouse staff.

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