Information
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Report Number
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Client / Site
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Address
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Conducted on
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Inspection conducted by
Relevant Information
ROUTINE INSPECTIONS
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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.
RECTIFICATIONS
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Repairs and rectifications to racking systems should only be undertaken by a trained and competent person. We recommend all works be completed in accordance with the time frames based on the colour coded level of damage.
Site Compliance Issues
Site 1
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Rack inspection check list
Serial
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Rack/s
- 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
- Rack JJ
- Rack KK
- Rack LL
- Rack MM
- Rack NN
- Rack OO
- Rack PP
- Rack QQ
- Rack RR
- Rack SS
- Rack TT
- Rack UU
- Rack VV
- Rack WW
- Rack XX
- Rack YY
- Rack ZZ
- Other
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Bay/s
- 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
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Observations
- Damaged
- Dislodged
- Missing
- Other
- Corrosion evident
- Incorrectly installed
- Non compliant - Manufactured prior to 1993 and can not be certified to current standards
- Incorrect component installed
- Buckled
- Dented
- Loose
- Twisted
- Distorted
- Cracked
- Incorrect bracing configuration
- Incorrect bracing node orientation
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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
- Column guard
- Pallet rail arm
- Pallet support bar
- Beam end connector
- Frame spacer
- Leveling plate
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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 90 x 40 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 90 x 40 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
- Top
- Entire rack structure
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Comments
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Rating
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Material/Manufacturer
- Keylock MK8
- Keylock MK6
- Keylock MK5
- 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
- Dexion Deepstore
- Other
- Unknown manufacturer
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Comments
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Recommended 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
- Install correct component
- Replace with new compliant system
- Contact original supplier for load data and SWL
- Install additional brace to strengthen front upright
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Comments
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Photo
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Rectifications completed by
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Signature
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Date completed
Additional Comments/Recommendations
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User manuals retained on site
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Racking plans retained on site
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Additional Comments
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Photo
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Inspectors Signature
The contents of this report have been discussed with the site contact. All damages and/or compliance issues requiring immediate action have been identified and brought to the attention of the undersigned.
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Client Signature
