Welcome to Session 217

Pallet Racks and Decking Considerations for Selecting, Installing, Maintaining and Operating
Presenters:

John Krummell Advance Storage Products Carlos Oliver Frazier Industrial Steve Johnson - Nashville Wire Products

Sponsored by:

2012 Material Handling Industry. Copyright claimed as to audiovisual works of seminar sessions and sound recordings of seminar sessions. All rights reserved.

Storage Racks - Applications Considerations & Developments

Presented by: John Krummell Advance Storage Products

About RMI
Independent, non-profit Trade Association Composed of the leading US and International Rack and Wire Deck Manufacturers. Formed in 1958
Welded Wire Decking Group incorporated in 2005.

Mission:
To advance standards, quality, safety and general fitness for intended use of Racking & Welded Wire Decking.

Who Are RMI Members

All of the leading US Pallet Rack and Wire Deck Manufacturers Up-to-date listing can be accessed at http://www.mhia.org/rmi

Why use Pallet Rack?

Correctly Applied Racks and Accessories will:
Utilize cubic space efficiently Double or triple pallet storage per square foot of floor space Help with inventory control Reduce product damage Enhance warehouse safety Provide flexibility for growth

Storage Racks - Types and Styles

Selective Rack:
100% access to all storage locations Most widely used system Wide range of accessories Standard components can be customized Very flexible

Storage Racks - Types & Styles

Double-Deep Rack:
2 pallets stored from the aisle
Requires pantograph fork lift

Floor space savings Good selectivity Slower throughput vs. single-deep & pushback

Storage Racks - Types & Styles

Drive-In /Drive-Through Rack:
High density Requires large number of pallets/SKU FILO or FIFO inventory schemes based on layout Standard handling equipment Medium throughput

Storage Racks - Types & Styles

Push-Back Rack :
High density
Up to 5 or 6 positions deep

High volume/Mid level SKU Each level is accessible Reasonable selectivity Standard handling equipment FILO inventory approach Excellent throughput

Storage Racks - Types & Styles

Pallet-Flow Rack:
High density, FIFO
Can be more than 25 pallets deep

High throughput Standard handling equipment Reasonably flexible

Storage Racks - Types & Styles

Cantilever Rack:
Long and irregular loads Full selectivity Standard or specialized handling equipment Floor space savings

Storage Racks - Types & Styles

Accessories: Solid and wire mesh decking Pallet-support bars Fork-entry bars Drum cradles Safety devices Many, many more..

New and Used Pallet Racks Safety, Installation and Maintenance Considerations
Presented by: Carlos Oliver Frazier Industrial

Why the Sudden Interest ?

More collapses occurring today Taller systems

Increased use of used rack

Worker, health and safety

 Why do collapses happen?

System Specifier
Miscommunication of design parameters Incorrect design of the system Incorrect truck clearances Reduce rack capacity in order to decrease price Incorrect use of repair kits

Regular Operations
Rack damage Incorrect load weight Altering of configuration Change in operation Incorrect use of equipment

Regular Operations
Pallet maintenance Change in equipment Lack of driver training

Mixing and matching of similar components from

different manufacturers

Manufacturer
Designed incorrectly Poor craftsmanship (AWS/ CWS standards)

Lack of clarity on design parameters

What should I do?

Take control of the situation Conduct a rack safety audit Develop a driver accountability strategy Develop an on-going rack safety audit program

Install and maintain capacity plaque

What are the steps included in the audit?

Locate and maintain initial design drawings and calculations Document existing elevations and layouts Determine if the current configuration is structurally sound Determine the extent of any damage

Develop a plan for repairing the rack

Maintenance
Ensure that the racks are inspected for damage on a periodic basis

Develop repair criteria for damage

Ensure that all re-profiling is reviewed by suppliers engineering department Repair kits should be designed by a qualified Professional Engineer and approved by the original rack manufacturer

Insist on driver training for all new operators

When damage occurs, immediately isolate the area and seek guidance from a qualified Professional Engineer on a repair or replacement protocol. RMI/ANSI MH16.1-2008 - Any damage must be repaired or replaced.

Repair Kits
Repair kits should be designed by a qualified Professional Engineer and approved by the original rack manufacturer to minimize owner risk of liability The bracing system should be designed in conjunction with the original frame

Safety Accessories Protect Your Rack System

Post protectors and bull noses protect the front column from damage by deflecting impact from pallets or fork trucks.

Boxing the front columns provides excellent fork truck impact resistance.

Safety Accessories Protect Your Rack System

Row end protectors provide protection against fork lift damage where it is needed most - at the end of the aisle. Rub rails are horizontal members that bolt into frames below the lowest horizontal. They protect the frame from damage by the fork truck or pallet in two ways; the rub rail helps distribute any impact forces to the rear column of the frame, and it prevents the column from rotating when hit.

Safety Accessories Protect Your Rack System

Safety Accessories Protect Your Rack System

The initial cost of a rack system is 3% of the total cost of operating a dry warehouse facility over its 30 year life. Sysco Foods

Peace of mind comes from a properly designed, installed, operated and maintained rack system

Welded Wire Rack Decking Applications & Safety Considerations

Presented by: Steve Johnson Nashville Wire Products

Pallet Rack Shelving

Options
No Supports

Pallet Rack Shelving

Options
Cross Bar Supports

Pallet Rack Shelving

Options

Solid Shelving

Pallet Rack Shelving

Options Wire Mesh Decking
THE ULTIMATE SAFETY SOLUTION!

Warehouse Safety & Liability

PALLETS LOADED DIRECTLY ON BEAMS

Vulnerable to the structural integrity of the pallet

Warehouse Safety & Liability

PALLETS LOADED DIRECTLY ON BEAMS
Wooden Pallets

Pallets too small or improperly installed

Wire Decking

Warehouse Safety & Liability

CROSSBAR SUPPORT Allows smaller materials to fall through

Wire Decking Provides Solutions

FOR SAFER INSTALLATION AND HANDLING OF SHIPPING PALLETS

THE ULTIMATE SAFETY SOLUTION!

Fire Codes
National Fire Protection Association

www.nfpa.org

FM Global

www.fmglobal.com

Intermediate Sprinkler Head

Solid Shelving Hides & Spreads Fire

Solid Shelving

FLAMES GROW UNDETECTED AND ARE OBSCURED FROM WATER

Wire Decking Reduces Fire Hazard

OPEN MESH PROVIDES QUICKER DETECTION AND EXTINGUISHING Eliminates the need for multi level sprinklers

Benefits of Wire Decking

Versatile storage options Capacity rating with engineered safety factor Meets fire codes Saves on insurance premiums ( vs. solid shelving) conforms to national & local codes Visibility Brighter cleaner warehouse Custom options and accessories Solves problems and promotes safety!!

Beam Section
Step Height
Step Ledge Beam Face Top of Beam

Step Beam

Beam Section
Top of Beam

Box Beam

Structural C Channel Beam

Typical Deck Design for 1 5/8 Step Beam

Wire mesh top with 1 1/2 double waterfall (front & rear waterfall) style Support channels to fit 1 5/8 step beams

Flared Support Channel for Structural and Box Beams

(Standard Flanged Style)

Inverted Channel Style

Inside Waterfall Style

Flat Flush Style

Waterfall With an Incorporated Backstop

Light duty backstops

Load Capacity
Capacity Definition: A maximum
independent of the support system.
recommended uniformly distributed static load

ANSI Standard MH26.2 Details

Design shall be based upon determination of capacity and allowable deflections. Designs shall be based upon uniformly distributed static loading. While welded-wire rack decking is generally designed for static uniformly distributed loads, manufacturers may be able to provide designs suitable for static concentrated loads upon special request. Welded-wire rack decking may not be suitable for dynamic loading

Uniformly distributed load

Definition-3.1.12 Any static load which is evenly distributed over the entire surface on the deck independent of the support system. Needs to be within 2 of each beam but does not have to rest on the beams

Examples of Non-Uniformly Distributed Loads

Loads other than uniformly distributed may require special designs 1 - Line Load 2 - Concentrated Load 3 - Point Load

Line Load
DefinitionA load that distributes its weight in a concentrated line vs. uniformly distributed

Could cause the wire to carry the entire load and increase risk of failure

Concentrated Load
DefinitionAny static load which is not uniformly distributed over the entire surface of the decking section.
Example a 2500 lbs barrel placed in the center of a deck

Point Loads
Definition A load that has its weight on individual points vs. uniformly distributed
Example A container with 4 contact points. All the points could be potentially on the wires only versus wires and channels

Deflection of 2 x 4 6 Gauge Deck

CAUTION!

Decking is not designed to be walked on. Walking creates dynamic point loads, far from an evenly distributed load.

Importance of Using R-Mark Certified Deck

Would you purchase a Rack System that did not meet the RMI/ANSI Standards ? Why would you purchase a deck that is designed, built, or rated by something other than the published American National Standard?

Benefits of Wire Decking

Versatile storage options Capacity rating with engineered safety factor Meets fire codes Saves on insurance premiums ( vs. solid shelving) Conforms to national & local codes Visibility Brighter cleaner warehouse Custom options and accessories Meets ANSI Standards Look for R-Mark Certifications!

Want More Information on Welded-Wire-Rack-Decking?

Visit www.mhia.org/rmi for a more information on members of the Rack Manufacturers Institute as well as valuable information to assist you in your selection.

Q&A

For More Information:

www.mhia.org/rmi or standards@mhia.org

Speaker: jkrummell@asprack.com cpo@frazier.com sjohnson@NASHVILLEWIRE.com Visit MODEX 2012 Booth 5406

2012 Material Handling Industry. Copyright claimed as to audiovisual works of seminar sessions and sound recordings of seminar sessions. All rights reserved.