While automation has helped make many processes more efficient, it has also created the problem of traffic in many a warehouse. As warehouse real estate has become pricier and pricier, it means companies have to find ways to manage this ‘traffic’ safely and efficiently. With innovations like double deep reach racking, very narrow aisle racking and mezzanines, we can pack more SKUs into smaller spaces.

But with this smaller footprint (and taller structures) comes an increased likelihood of a racking collapse. All it takes is a nudge on a weakened support column and the ensuing collapse puts people, goods and equipment in danger.

The advantage that forklifts grant any distribution firm can’t be denied, but they are also responsible for a large number of accidents. Many firms do stick to the prescribed safety guidelines of:

• Regularly testing drivers for competence,
• Clearly marking out pedestrian crossing points and traffic routes,
• Providing adequate lighting on the warehouse floor.

But despite this, accidents still occur regularly. This year alone, there have been 25 firms prosecuted and fined for causing injury via unsafe working conditions. Even with sums ranging from £ 12, 000 to £ 60, 000 paid as compensation, it does little for the 10 families that have lost a loved one. Add the downtime to the business and damage to the facility, and forklift accidents become a costly headache.

Speaking of damage to the facility, racking collapse is almost always a result of getting rammed by a motorized vehicle. We know it’s almost impossible to avoid any impact so we advise firms to ensure that any damage incurred is minimal and has a non-disruptive effect on production.

Common Causes of Warehouse Racking damage

Racking damage occurs most frequently, at the end of a pallet rack; as that’s usually where forklift drivers over-estimate the available turning radius.

1. Whacking the tines of the forklift into the uprights of any rack, even at 5 mph, will cause damage. Even if it isn’t evident at first, the structure will be weakened to a degree.
2. Some forklift drivers are known transport loaded pallets in a ‘chain’, by lining them up and pushing along the warehouse floor. With the 4.5 tone machine behind it, even a flimsy pallet can damage the lower parts of a pallet rack.

Common Protective Solutions

• One common form of protection is by bolting a high-strength steel angle or bar, between two uprights, but at the base of a racking column. Another option is the floor stop bollard, a 5 inch steel tube filled with concrete and bolted to the floor. As these options are close to the floor, they are best used in environments where space is limited.
• In less cramped conditions, (where the drivers tend to speed more), racking is best protected using steel low-profile rails. These are corrugated steel rails bolted to tubular columns, 18 to 42 inches tall. The columns are welded to steel base plates, anchored to the floor with heavy-duty bolts.

These barriers can be set up in custom configurations to create angled barriers or a compound barrier, depending on the position of the column that needs protecting. The barriers can either be set up in aisles, protecting the base of the racking or at high traffic angles.

• In situations like around corners, a long barrier may not be practical to install. In its place, a single safety bollard can be bolted to the ground, a few inches from the racking that is to be protected.

There are two more common rack protectors, but they have slight disadvantages:

• While shock-absorbing rack guards can protect pallet racks, their low profile makes them ineffective if the forklift drives with tines raised.
• The HDPE rack mounted guard is easy to install and protect the column from bumps, but it can rip relatively easily, thus rendering it ineffective.

Regardless of the rack protection used, it is advised that they are painted in bright colours with a powder coating. The colour (‘Minion-yellow’) serves as a very visual ‘barrier’, and the coat ensures that the protective equipment lasts for a long time.

While these solutions may seem extremely low-tech, they’re the best protection for shelving. Avoid the horror of injury, paying compensation and the downtime associated with a racking collapse.

Contact Monarch Limited today for custom guard rails, machine guards and other protective supplies. For questions or more information regarding our warehouse storage, call us today.