Information
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Report number
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Client / Site
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Conducted on
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Inspection conducted by
- Steve Williams
- Josh Costabeber
- Cazna Bocking
- Dave Royle
- Peter Saliba
- Nicky Clarke
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Location
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Site contact
Disclaimer
Disclaimer
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The assessors believe the information contained within this risk assessment report to be correct at the time of printing. The assessors do not accept responsibility for any consequences arising from the use of the information herein. The report is based on matters which were observed or came to the attention of the assessors during the day of the assessment and should not be relied upon as an exhaustive record of all possible risks or hazards that may exist or potential improvements that can be made.
• This inspection was conducted whilst the racks were 'Fully Loaded'. Due to the product loading there is no guarantee that all faults have been identified.
• It is the Clients responsibility to ensure that the recommendations within this report are actioned.
A person conducting a business or undertaking who alters or modifies a rack design without consulting the original or subsequent designer will assume the duties of a designer. Any changes to the design of a structure may affect the health and safety of those who work on or use the structure and must be considered by the person altering or modifying a design.
Information on the latest works compensation and OHS / WHS laws can be found at the relevant state WorkCover / WorkSafe Authority.
Confidentiality Statement
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In order to maintain the integrity and credibility of the risk assessment processes and to protect the parties involved, it is understood that the assessors will not divulge to unauthorised persons any information obtained during this risk assessment unless legally obligated to do so.
Routine inspection
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It is recommended that the end user refer to Section 8 - “Operation and Maintenance of Adjustable Pallet Racking” of AS4084 (Steel Storage Racking) for racking inspection and
maintenance procedures. As a supplement to the code recommendation, the following information has been compiled based on AS4084 and the FEM recommendation. For your information, FEM (Federation Europeene de la Manutention) is a European industrial body made up from various national organisations representing the storage equipment manufactures in their own country.
The Pallet Racking system requires no maintenance, other than to replace possible damage through incorrect operation. The system should be regularly inspected.
RACK SAFETY OFFICER / REPORTING PROCEDURE
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It is recommended that a ‘Rack Safety Officer’ is appointed and a procedure put in place so that any damage or unsafe occurrence can be reported, thus ensuring that any necessary actions can be taken to maintain a safe working environment.
The safety officer would undertake routine inspections, keeping maintenance and safety reports.
COLOUR CODING FOR RISK IDENTIFICATION
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The following colour coding; Green, Orange, and Red are classifications of risk as defined by FEM ‘Guidelines for the Safe Use of Static Racking’
Green Risk: Damage requiring surveillance.
Orange Risk: Hazardous damage requiring action as soon as possible.
Red Risk: Very serious damage requiring immediate action.
COLOUR CODE DEFINITIONS
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GREEN RISK:
Damage requiring surveillance.
For damage to frames in which the limits are not exceeded. This would indicate racks where some damage was present but was considered non-critical.
Such damaged components should be recorded as suitable for further service until the next management inspection, but clearly identified for further re-examination at future inspections.
ORANGE RISK:
Hazardous damage requiring action as soon as possible.
For damage to frames in which the limits are exceeded by up to a factor of two. This would identify an area where the damage was sufficiently severe to warrant remedial work but not so severe as to warrant the immediate off-loading of the rack. Once the rack is unloaded however, it should not be re-loaded until repairs have been carried out. In the event that the storage position remains full for several days after the initial identification of the problem, the rack should be off-loaded for repair without further delay.
The USER company must have a method of isolating such racks to ensure that they do not come back into use until the necessary repairs have been carried out and the equipment certified as safe. For example, use could be made of dated adhesive labels, which indicate racks that are not to be re-loaded until rectified. In practice any racking with ORANGE RISK category damage should be re-designated RED RISK damage if remedial work has not been carried out within four weeks of the original designation.
RED RISK:
Very serious damage requiring immediate action.
For damage to frames in which the limits exceed a factor greater than two.
These are situations where a critical level of damage is identified which warrants an area of racking being immediately off-loaded and isolated from future use until repair work is carried out. Such repair work would involve replacement of the damaged item.
USER companies must have a method of isolating areas to ensure that they do not come back into use prior to the repair work being carried out. For example, a particular bay could be off-loaded in the presence of the inspector and roped off to prevent further use.
INSPECTION INTERVALS
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Daily Inspections
This applies to operator care of the system.
_ Ensure the correct application and use of equipment.
_ Ensure that the safe working loads are adhered to.
_ Damaged pallets must not be entered into the system and should be removed as they occur.
_ Any safety issues or damage to the structure should be reported to the Safety Officer who will carry out the risk assessment and identify the risk as necessary.
Weekly Inspections
The Safety Officer will perform visual inspection carried out from ground level of all the racking.
This should include all forms of accidental damage classed as Red or Orange Risk.
Monthly Inspections
This should be carried out in a similar manner to the weekly inspection, but include the physical emptying of random bays in order to carry out a more detailed inspection.
_ It should also be used to check that items already identified as Red Risk have been isolated with the necessary actions taken to rectify the risk. Similarly Orange Risk items should be checked to ensure repairs are underway.
_ Ensure that all safe working load signs, maintenance and other safety signs are in place.
Six to Twelve Monthly Inspections
Must be completed at least once every Twelve months. A major inspection by a technically competent person fully experienced in the identification and categorisation of rack damage. Such a person may be an external specialist capable of giving an independent assessment of the racking. This review should also examine the performance of the reporting procedures and that actual repairs are being carried out.
The inspection should be comprehensive and include checking for out-of-plumb and ensure that the rack installation has not been altered. A copy of the load application and configuration drawings shall be retained for this purpose.
Site 1
Site 1
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Rack inspection check list
Serial
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Rack
- Rack A
- Rack B
- Rack C
- Rack D
- Rack E
- Rack F
- Rack G
- Rack H
- Rack I
- Rack I
- Rack J
- Rack K
- Rack L
- Rack M
- Rack N
- Rack O
- Rack P
- Rack Q
- Rack R
- Rack S
- Rack T
- Rack U
- Rack V
- Rack W
- Rack X
- Rack Y
- Rack Z
- Rack AA
- Rack BB
- Rack CC
- Rack DD
- Rack EE
- Rack FF
- Rack GG
- Rack HH
- Rack II
- Other
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Rack
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Bay
- Bay 1
- Bay 2
- Bay 3
- Bay 4
- Bay 5
- Bay 6
- Bay 7
- Bay 8
- Bay 9
- Bay 10
- Bay 11
- Bay 12
- Bay 13
- Bay 14
- Bay 15
- Bay 16
- Bay 17
- Bay 18
- Bay 19
- Bay 20
- Bay 21
- Bay 22
- Bay 23
- Bay 24
- Bay 25
- All bays
- Multiple bays
- Other
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Bay
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Observation
- Damaged
- Dislodged
- Missing
- Other
- Corrosion evident
- Incorrectly installed
- Non compliant - Manufactured prior to 1993 and can not be certified to current standards
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Comments
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Item
- Beam
- Upright
- SWL sign
- Diagonal brace
- Horizontal brace
- Nut
- Bolt
- Baseplate
- Baseplate anchor bolt
- Frame
- Mesh deck
- Rack end protector
- Upright protection
- Beam safety clip
- Shelf
- Shelf Clip
- Kick Plate
- Back Sheet
- Column
- Storage Arm
- Base
- Back Bracing
- Pallet Rail
- Beam Locking Screw
- Other
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Specifications
- Other
- 2438 90R Blue
- 2438 90R Pgal
- 3048 90R Blue
- 3048 90R Pgal
- 3658 90R Blue
- 3658 90R Pgal
- 4267 90R Blue
- 4267 90R Pgal
- 4877 90R Blue
- 4877 90M Blue
- 4877 90H Blue
- 4877 90R Pgal
- 4877 90M Pgal
- 4877 90H Pgal
- 6096 90R Blue
- 6096 90M Blue
- 6096 90H Blue
- 6096 90R Pgal
- 6096 90M Pgal
- 6096 90H Pgal
- S8 2400 90G Pgal
- S8 2400 90R Blue
- S8 2400 90R Pgal
- S8 3000 90G Pgal
- S8 3000 90R Pgal
- S8 3000 90R Blue
- S8 3600 90G Pgal
- S8 3600 90R Pgal
- S8 3600 90R Blue
- S8 4200 90G Pgal
- S8 4200 90R Pgal
- S8 4200 90R Blue
- S8 4800 90G Pgal
- S8 4800 90R Pgal
- S8 4800 90R Blue
- S8 6000 90R Pgal
- S8 6000 90M Pgal
- S8 6000 90H Pgal
- S8 6000 90R Blue
- S8 6000 90M Blue
- S8 6000 90H Blue
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Specifications
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Component notes
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Component notes
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Specifications
- Other
- 1372 x 50 open
- 1372 x 75 open
- 2591 x 75 open
- 2591 x 105 I
- 2591 x 83 Box
- 2591 x 85 Box
- 2591 x 93 Box
- 2591 x 95 Box
- 2591 x 102 Box
- 2591 x 105 Box
- 2591 x 110 Box
- 2591 x 120 Box
- 2591 x 140 Box
- 2591 x 100 x 50 x 2.5 RHS
- 2591 x 100 x 50 x 4 RHS
- 2743 x 75 open
- 2743 x 105 I
- 2743 x 83 Box
- 2743 x 85 Box
- 2743 x 93 Box
- 2743 x 95 Box
- 2743 x 102 Box
- 2743 x 105 Box
- 2743 x 110 Box
- 2743 x 120 Box
- 2743 x 140 Box
- 2743 x 100 x 50 x 2.5 RHS
- 2743 x 100 x 50 x 4 RHS
- S8 1350 x 50 Open
- S8 1350 x 75 Open
- S8 2600 x 105 I
- S8 2600 x 85 Box
- S8 2600 x 95 Box
- S8 2600 x 105 Box
- S8 2600 x 140 Box
- S8 2600 x 100 x 50 x 2.5 RHS
- S8 2600 x 100 x 50 x 4 RHS
- S8 2750 x 75 Open
- S8 2750 x 105 I
- S8 2750 x 85 Box
- S8 2750 x 95 Box
- S8 2750 x 105 Box
- S8 2750 x 140 Box
- S8 2750 x 100 x 50 x 2.5
- S8 2750 x 100 x 50 x 4 RHS
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Specifications
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Location
- Lower
- Upper
- Front
- Rear
- Left hand
- Right hand
- Level 1
- Level 2
- Level 3
- Level 4
- Level 5
- Level 6
- Level 7
- Level 8
- Level 9
- Level 10
- Level 11
- Level 12
- Level 13
- Level 14
- Level 15
- Other
- Multiple locations
- End of rack
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Rating
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Material/Manufacturer
- Keylock MK8
- Keylock MK6
- Keylock MK3
- Speedlock MK8
- Colby
- APC
- Mack Rack
- Spacerack
- Brownbuilt
- Schaffer
- Stow
- Acrow
- Emrack
- Sipag
- Steel Built
- Dexion Longspan
- Dexion CI-80 Ultima
- Plan D
- Dexion DCP
- Dexion HD Cantilever
- Keylock MK5
- Dexion Deepstore
- Other
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Comments
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Reccomended Actions
- Replace with new component
- Install IAW manufacturers specification
- Remove and reinstall IAW manufactures specifications
- Remove and discard
- Dismantle and dispose
- Monitor only
- Other
- Invert and reinstall
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Comments
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Photo
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Rectifications Completed
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Signed off by
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Date
Additional Comments/Reccomendations
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Additional Comments
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Photo
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Signature
