How much difference can a fully enclosed pallet rack upright make? When it comes to the kind of significant injuries, product damage, and overall safety of a warehouse or commercial facility, the minor cost differences are insignificant compared to the potential savings if you prevent just one accident over the next decade. Imagine suffering an accident like this one, or this one, and it being preventable.

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According to DC Velocity, the answer may be yes.

The maker of several over-the-counter drugs, including Tylenol, Motrin and Benadryl, announced a broad-based recall of these and other drugs after receiving complaints of an “unusual moldy, musty or mildew-like” odor. Johnson & Johnson received what the company described as a “small” number of complaints of issues including nausea, stomach pain, vomiting or diarrhea.

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This is a great video from WorkSafeBC on how to prevent forklift injuries from a pedestrian’s point of view.

As a pedestrian in a forklift environment, it’s your responsibility to keep yourself safe.  Anyone who runs a warehouse or industrial facility understands the dangers, and drivers should be trained. But do you train the pedestrians, the order pickers, the managers, and vendors who sometimes roam your facility?

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If you’ve ever stopped at a traffic light, and shuddered at the texting, teenage driver in the next lane, you probably thought this is an irresponsible person who shouldn’t be behind the wheel. Given statistics that texters are about as impaired as drunk drivers, it’s a real issue. The question is, do you tolerate that kind of distractions for forklift drivers in your warehouse?

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Talk about your ounce of prevention pound of cure scenario…

This forklift accident illustrates the importance of properly protecting the ends of pallet rack rows. The driver didn’t have much room to accelerate, but didn’t need much velocity to hit the rack hard enough to compromise the upright and start a domino effect that destroyed hundreds of thousands of dollars of alcohol (this was a Russian company, but forklift damage knows no national boundaries) and endangered warehouse employees. Utilizing bollards, steel guard rails, or upright rack frame post protectors might have prevented it.

It may also stress the importance of specifying sufficiently collision-resistant racks, such as heavy duty high-strength structural racks or totally-enclosed tubular uprights. Rack is often seen as a “stack it high” commodity, but in situations like that video, the value of correct specification and safety measures are underlined. If you have damaged uprights or unprotected rack columns, watch the video. And then get it fixed.

Push back rack systems are excellent high density storage solutions — perhaps the most economical way to squeeze space out of a crowded warehouse.  All loads are stored and retrieved from the same aisle. This reduces the number of aisles needed in a facility, freeing up more space for storage. Aisles can take a great deal of space up in a typical warehouse, so by implementing a pushback pallet rack system, you essentially swap selectivity for space. Push back rack systems provide a Last-In-First-Out (LIFO) inventory rotation, so you have to be certain your load fits. If it does, congratulations — you’ve just saved a lot of space. But there are issues that can arise when pushback rack is inappropriately specified or utilized. Here are some of those…

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You’ve probably heard it a hundred times: if you have forklifts in your facility, they are likely the most dangerous piece of equipment there. Accounting for 680,000 accidents, 95,000 injuries and nearly a hundred deaths every year, forklifts are a necessary but perilous piece of handling equipment. This is why people buy things like rack upright guards or steel guard railing – to keep them from hitting people, warehouse racks, equipment and storage media. Etcetera Software has developed a simulator for forklift drivers that you could find useful if you’re dealing with lift truck drivers.

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Nomination: Space above the dock doors

Next time you’re standing there wondering where you’re going to put an inbound shipment while your dock is stacked with empty pallets, look at those doors (or at the void above them)  –  the copious space between the top of the doors and the ceiling is unused. Multiply each door by that amount of space, and in many operations, we’re talking serious amounts of unused square footage.

The easy solution: find a use for it with over-dock-door storage. You can’t really rack heavy stuff up there without some significant structure. The best thing to consider is empty pallets, which take up a ton of room and are relatively lightweight. And usually, they’re all over the floor and always in your way. Empty pallets clutter up the shipping & receiving docks or can take up positions in your racks that would be better suited to full pallets of finished goods or incoming shipments.

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The Material Handling Industry of America recently announced that the RMI (Rack Manufacturers Institute) has certified several manufacturers of wire rack decking “R-Mark” compliant, meaning that these companies have conformed to the Institute’s testing and utilization standards. The industry developed the latest and most comprehensive consensus documents ANSI MH16.1 – 2008 – Specification for the Design, Testing and Utilization of Industrial Steel Storage Racks and MH26.2 – 2007  – Specification for the Design, Testing and Utilization of Welded Wire Rack Decking. Members of RMI voluntarily choose to conform to ANSI MH16.1 – 2008 and MH26.2 – 2007 and any successor document(s).

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Since overloading is a common source of pallet rack collapses, (in fact misapplication, including capacity issues, is the top cause) it’s important to understand how much weight your rack – not just your beams – can bear.

For a piece of storage equipment that is relatively simple, ensuring that the rack can hold what you want it to hold is sometimes complex – particularly on very heavy loads, or large but not so heavy loads. This article focuses on upright frame capacities. Beam capacities are pretty simple – they’re listed per pair of beams by most rack sellers, and you just adhere to them with your pallet loads. But frame capacity is not as straightforward as a beam capacity…

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