While much needs to be tended to in a warehouse, pallet rack safety should be a concern for all those who work with or near a racking system. Warehouses are bustling with the constant movement of people, merchandise, and equipment, creating an environment that can easily go unnoticed, allowing damage to occur.
The Occupational Safety and Health (OSH) Act of 1970 requires employers to provide a workplace free from known hazards to their employees. These hazards are defined as "those likely to cause serious physical harm or, in the worst case, death." Over the last four decades, significant progress has been made in workplace safety, thanks to the efforts of employers, health and safety professionals, unions, and advocates. Worker injuries and illnesses were down from 10.9 incidents per 100 workers in 1972 to 2.8 per 100 workers in 2017.
While OSHA continues to encourage employers and employees to reduce workplace hazards, it does not provide clear guidelines regarding pallet rack safety and damage specifically. Thus, it is up to companies and warehouse managers to acknowledge the risks posed by rack damage and proactively prevent them from occurring. In "Material Handling and Storage," an industry document published by OSHA, they broadly cover the precautions employers and workers can take to avoid "storage hazards." Figuring out, in practical terms, what these hazards might be and how to address them is primarily left to the user.
Not convinced it’s an important issue? Perhaps these videos will change your mind...
The collapse of a racking system can lead to costly repairs, insurance claims, liabilities, loss of productivity, or, worse yet, loss of life. Accumulated damage and inaction can heighten the risk level in your warehouse, cause delays in your operations if your racks need to be offloaded, and prevent you from using valuable storage space, all of which can hurt your bottom line. So where does one start?
A good first step is to schedule a baseline survey or assessment of your racking systems to get a clear picture of the state of your racks. This can be done by your maintenance personnel, using a checklist, or by a specialist knowledgeable in the field of pallet racking systems. Upon visiting your warehouse, the specialist may recommend a conformity inspection, performed by a specialized engineer, resulting in a detailed and actionable report listing all issues found.
Take a good look at the issues found. The damage identified as being a high priority should be labeled as such, and the affected portion of the rack can be unloaded as a preventive measure. If you were handed a long list of damages, target key problem areas and high-priority items first. Pay attention to high traffic zones where repeated damage has occurred.
Repair or replace damaged components and protect your racks against future impact. This infographic compares both options and explains how rack repair offers several advantages over replacing damaged components with the original equipment manufacturer’s parts.
Communicate your safety goals and onboard your workers by making it easy for them to report damage. Damage will go unreported unless those who work around the racks are aware of what to look for and can quickly alert management.
This is a difficult one. It can be done through employee training, measuring success, and rewarding employees for maintaining a safer warehouse.
Most accidents can be prevented by first acknowledging their prevalence and the risks they pose, and then implementing programs to mitigate them before they occur. Damotech can help you build a pallet rack safety program or assess your rack systems. Start by talking to one of our experts.