New Employee Training: Teaching The Basics Of Rack Safety

According to 2021 data from the U.S. Bureau of Labor Statistics (BLS), the average rate of recorded injuries among warehousing employees was 5.5 per 100 full-time workers. This marked a 23% increase (122,700 cases) in days away from work compared to 99,800 cases in 2020. This underscores the importance of training employees on the correct use of warehouse equipment, including fundamental rack safety practices.

 

Regardless of the type of industrial steel storage rack in a facility—whether it is selective, drive-in, pushback, pallet flow, cantilevered, drive-thru, dual-bay, or another system—there are essential safety practices to follow.

 

Any employee who interacts with a rack system as part of their job needs training on what constitutes safe interaction with the rack,”. “This mainly applies to forklift drivers and order selectors or pickers who navigate aisles and fill orders. However, everyone in the facility has a responsibility to notify managers or supervisors of unsafe situations. Therefore, it’s crucial for all new employees to learn the basics of rack safety.

 

Safe Loading and Unloading of Rack

Teach forklift operators how to properly load and unload pallet racks. This includes learning how to place unit loads onto the beams to prevent the load from falling and demonstrating how to remove loads without dislodging the beams.

 

Whenever possible, racks should be loaded from the bottom level upward. Additionally, loads should be positioned as uniformly and symmetrically as possible.

 

“Manufacturers design pallet rack beams to handle uniformly distributed loads, meaning the weight is evenly spread over the entire beam length. A point load, on the other hand, has its weight significantly concentrated in one or more places on the rack’s beams,”.

 

Placing a point load in a rack designed for uniformly distributed loads can cause excessive beam deflection (bowing) and/or system failure. “For example, even if the beams’ capacity rating is 7,200 pounds, placing one 6,000-pound load in the middle creates a point load that could cause the beams to fail,”. “Train forklift operators to place two 3,000-pound loads side-by-side in a storage bay to distribute the weight evenly.”

 

Follow Load Plaque Guidance Prevent Rack Overloading

To assist forklift operators in properly loading a rack structure, direct them to load capacity plaques mounted on or near the system. According to American National Standard ANSI MH16.1: Design, Testing, and Utilization of Industrial Steel Storage Racks, these load plaques must:

• Be a minimum of 50 square inches in size.
• Include the maximum permissible unit load (the combined weight of the product and its storage container or pallet) and/or the maximum uniformly distributed load per level.
• Detail the average unit load, if applicable (calculated as the maximum total weight of the product expected on all beam levels in any row, divided by the number of beam levels in that row).
• Indicate the total actual loading expected in interconnected bays.
• Display the maximum total load per bay.
• Indicate which storage levels allow multiple stacking of unit loads.

Avoid Impacts to Rack

Any rack impacted by a forklift is likely to sustain damage. Depending on the collision’s force, beams and column connections could become disengaged, anchor bolts loosened, columns bent, or the rack section could collapse. The damage may be either difficult to spot or clearly visible. Educate forklift operators to navigate through rack aisles and around corners with caution, and train them to avoid hitting the racks with the load, forks, or vehicle.

 

“Rack columns and beams are sometimes incorrectly used by forklift operators as a guide rail when placing a load into a rack,”. “Drivers will push the load against the rack structure to help them feel their way into proper position. This is a bad practice that will result in rack damage. Train drivers to place loads properly.”

 

Report Rack Damage Immediately

Train and encourage both forklift drivers and other personnel to report any impacts or observed rack damage to managers or supervisors immediately.

 

“Not every employee feels comfortable admitting they hit a rack with a forklift. Therefore, it’s crucial to create a culture where they can report an accident without fear of losing their job,”. “Additionally, inform other employees that if they see rack damage, they need to report it promptly. Then, rope off the area until the issue is addressed.”

 

Best practice is to have a policy or procedure in place for reporting rack damage when it occurs or upon discovery. Routine inspections for signs of rack damage are also essential.

 

Never Climb On or Into Rack

For their safety, pickers and other employees should never climb on or into a rack structure for any reason. Additionally, wire rack decking is not a suitable walking surface. Instead, provide poles with hooks to pull fallen products forward.

 

If a pallet jam occurs in a pallet flow rack, use one of four techniques (plugging, force loading, adjacent lane clearing, or pick face loading) to resolve the issue. Similarly, to resolve a jam in a pushback rack, follow the recommended best practices—none of which require an operator to climb into the structure.

 

FAQ’s

 

What is the average rate of recorded injuries among warehousing employees?

According to 2021 data from the U.S. Bureau of Labor Statistics (BLS), the average rate of recorded injuries among warehousing employees was 5.5 per 100 full-time workers.

 

Why is training on warehouse equipment and rack safety important?

There was a 23% increase in days away from work due to injuries in 2021 compared to 2020. Proper training on the use of warehouse equipment and rack safety practices is crucial to prevent such injuries and maintain a safe working environment.

 

What types of industrial steel storage racks require adherence to safety practices?

Safety practices are essential for all types of industrial steel storage racks, including selective, drive-in, pushback, pallet flow, cantilevered, drive-thru, dual-bay, and others.

 

Who needs training on safe interaction with rack systems?

Any employee who interacts with a rack system as part of their job, including forklift drivers, order selectors, and pickers, needs training on safe interaction. Additionally, all employees should be aware of basic rack safety and report unsafe situations.

 

What are some key practices for safely loading and unloading pallet racks?

Forklift operators should learn to place unit loads onto beams to prevent them from falling and to remove loads without dislodging beams. Racks should be loaded from the bottom level upward whenever possible, and loads should be positioned uniformly and symmetrically.

 

What is the difference between uniformly distributed loads and point loads?

Uniformly distributed loads have their weight evenly spread over the entire beam length, while point loads have their weight significantly concentrated in one or more places on the rack’s beams. Point loads can cause excessive beam deflection and system failure.

 

How can forklift operators avoid overloading racks?

Forklift operators should follow the guidance on load capacity plaques mounted on or near the rack system. These plaques include information on maximum permissible unit loads, maximum uniformly distributed loads per level, and other essential loading information.

 

What should be done if a rack is impacted by a forklift?

Any rack impacted by a forklift should be reported immediately to managers or supervisors. The affected area should be roped off until the issue is addressed. Routine inspections for signs of rack damage are also important.

 

How should employees report rack damage?

Employees should be trained and encouraged to report any impacts or observed rack damage immediately. Creating a culture where employees can report accidents without fear of losing their job is crucial. A policy or procedure for reporting rack damage should be in place.

 

Why should employees never climb on or into rack structures?

For their safety, employees should never climb on or into rack structures. Wire rack decking is not a suitable walking surface. Instead, poles with hooks should be provided to pull fallen products forward.

 

What are some techniques for resolving pallet jams in pallet flow racks?

Techniques for resolving pallet jams in pallet flow racks include plugging, force loading, adjacent lane clearing, and pick face loading. None of these techniques require an operator to climb into the structure.

 

Conclusion

Ensuring the safety of warehousing employees requires comprehensive training and adherence to rack safety practices. The rise in injuries highlights the need for proper equipment use and prompt reporting of any damage. By following these guidelines, warehouses can reduce accidents, protect employees, and maintain efficient operations.