How To Install Pallet Racking Systems

Key Takeaway:

Proper installation of pallet racking systems is essential for warehouse safety and  OSHA regulations.

Introduction

A well-installed racking system ensures safe and organized storage and handling of cargo. This guide provides detailed instructions on how to install pallet racking systems, highlighting the importance of compliance with OSHA requirements to create a safe working environment for employee.

Pre-Installation Preparation

Training and Safety Procedures

Before beginning the installation, it is crucial to train your crew on safety procedures. Proper training helps create a safe working environment and ensures that everyone understands the necessary steps for a successful installation. Emphasize the importance of wearing safety gear, such as hard hats, gloves, and safety boots, and following all safety protocols.

Inspecting Rack Materials

Inspect all rack materials thoroughly and compare them with the project documentation. Ensure you have all the necessary materials for the installation. If you detect any shortages or damaged materials, contact the shipper immediately to resolve these issues. Using damaged materials can lead to structural failures and safety hazards.

Assessing the Installation Site

Assess the installation site to ensure the floor can support the load from each fully loaded rack column. A concrete floor slab of around six inches is typically necessary for standard pallet racks. Ensure the floor is level and free from obstructions such as electrical panels, piping, lights, and ducts. Flag any obstructions with tape to avoid complications during installation.

Installation Process

Establishing Starting Line and Layout

Begin the installation by establishing a starting line for the racking system. Create chalk lines to mark the floor layout, ensuring the aisle widths adhere to OSHA guidelines. Place down-aisle chalk lines along the front face of each rack column from the start line.

Erecting the First Rack Bay (Starter Bay)

Erect the first rack bay and verify that all beam elevations are accurate. Confirm the layout with the site contact person if available. Achieving a plumb installation in both the cross-aisle and down-aisle directions is critical. Use shims to ensure the racking lays flat and is upright. Once confirmed, tighten all bolts securely.

Installing Connectors (T-Blocks, Wedge Locks, etc.)

Install connectors such as T-bolts or wedge locks according to the specific requirements of your racking system. Ensure the correct number of T-bolts for each connector. Proper installation of connectors is crucial to prevent shortages and delays in the installation process. Correctly tighten the T-bolts and wedge locks to the specified torque values to avoid structural issues.

Rack Anchoring and Compliance

Proper Anchoring Techniques

Proper anchoring is essential to ensure the stability and safety of the racking system. Use a single anchor bolt for every column, ensuring it has a 0.5-inch diameter and provides 2.5 inches of nominal embedment under the floor. For base plates with four holes, use two or more anchors per column. Follow the manufacturer's instructions for anchor bolt placement and torque values to avoid over-tightening and potential structural failures.

Recommended Anchor Types and Embedment

Ensure the anchor bolt's length matches the necessary embedment, considering the base plate thickness. While anchoring is recommended for most racking systems, it may be bypassed for racks less than eight feet tall in areas with low seismic activity. Always refer to the manufacturer’s guidelines for specific recommendations on anchor types and embedment depths.

Compliance with OSHA Requirements

Compliance with OSHA requirements is crucial for maintaining a safe working environment. Ensure sufficient clearances at doorways, loading docks, and aisles where mechanical handling equipment is used. Keep storage areas free from materials that could cause tripping or fire hazards. Regularly inspect the racking system to ensure it remains in compliance with OSHA standards and industry regulations.

Installation of Remaining Bays and Accessories

Installing Additional Frames and Back Connectors

Once the starter bay is installed, proceed with installing additional frames. Ensure all frames are plumbed in both the cross-aisle and down-aisle directions. Anchor the footplates for each bay similarly to the starter bay. Install back connectors loosely at first, tightening them only after the entire rack row is in place. Ensure the back connectors are uniformly spaced.

Installing Column Protectors and Shelf Accessories

Consider how column protectors will be installed before anchoring the racks. Some column protectors require anchor bolts. After installing the beams and rack row frames, place any shelf accessories, such as wire decking and crossbars, in the correct positions. Non-waterfall wire decks must be Tek-screwed to ensure they cannot fall between beams.

Installation Tips for Various Pallet Racks

Mezzanine Pallet Racks

When installing mezzanine pallet racks, ensure the structure is stable and secure. Verify that the mezzanine floor can support the intended load. Properly anchor the mezzanine posts to the floor and cross-brace the structure to prevent sway.

Carton Flow Racks

For carton flow racks, ensure the rollers are correctly aligned and installed at the proper angle to allow smooth product flow. Verify that the end stops are secure to prevent cartons from falling off the rack.

Cantilever Racks

Install cantilever racks with proper spacing between the arms to accommodate the load. Ensure the base is adequately anchored to the floor to prevent tipping. Check that the arms are level and securely attached to the uprights.

Selective Pallet Racks

Selective pallet racks should be installed with enough aisle space for forklift access. Ensure the beams are securely locked into place and the safety clips are engaged. Regularly inspect the racks for damage and make necessary repairs.

Teardrop Pallet Racks

When installing teardrop pallet racks, ensure that all connector pins are properly placed in the columns. Inspect the safety locks to ensure they are functioning correctly. Confirm that the beams are level and securely fastened.

FAQ

1. What are the OSHA requirements for pallet racking installation?

OSHA requires sufficient clearances at doorways, loading docks, and aisles where mechanical handling equipment is used. Storage areas must be free from materials that could cause tripping or fire hazards. Material storage should not create a hazard.

2. How do I ensure my pallet racking system is level?

Use shims to achieve a level installation. Ensure the racking is plumb in both the cross-aisle and down-aisle directions. Regularly check the level during installation to prevent future issues.

3. What should I do if my rack materials are damaged?

If rack materials are damaged, contact the shipper immediately to resolve the issue. Do not use damaged materials, as they can lead to structural failures and safety hazards.

4. How often should I inspect my pallet racking system?

Inspect your pallet racking system regularly to ensure it remains in compliance with OSHA standards and industry regulations. Regular inspections help identify and address potential issues before they become serious problems.

5. What types of anchors are recommended for pallet racking systems?

The recommended anchor type depends on the specific requirements of your racking system. Use anchor bolts with a 0.5-inch diameter and provide 2.5 inches of nominal embedment under the floor. Follow the manufacturer’s guidelines for specific recommendations.