Why pallet rack collapses need not be worst warehouse nightmare

 Unique system offers full protection

After warehouse fires every manager's worst nightmare is a domino-style racking collapse but in one sense the latter is worse. Fires can be quickly detected and contained by sprinklers and other devices but total racking collapses cannot when, for example, forklifts hit upright posts (legs) and that is where RCP's* patented, unique Rhino system comes in. Until five years ago all pallet protection measures outside of best practices depended  on post protectors, bollards and guard rails but these offered very  limited post protection to no more than about 1.2mt above ground. The Rhino system, however, suitable for both new-builds and retrofits, uses steel cables suspended from roof structures to the upright aisle posts so that it does not transfer the compromised rack load but stops it leaning past the point of no return, thus preventing progressive rack collapse. 

One of RCP's latest Rhino contracts is for garden shed supplier Kybotech, of Worksop, whose 20,000+ pallet store typically has a top beam height of 14mt, served by Bendi articulated forklifts in 2.6mt wide aisles. Pallet weights are typically 600kg and some pallets are special sizes for abnormal loads. Kybotech sell to the trade on timed deliveries, which stresses the importance of uninterrupted deliveries. Before the Rhino installation Kybotech's racking safety measures comprised routine inspections and rack leg guards, very common throughout warehousing. Previous rack damage was dents from small impacts on the lower legs, which if undetected can cause rack failure. So why did Kybotech feel the necessity to step outside the safety norm?

"Safety for its employees was paramount above all else," explained Craig Atwell, RCP's MD. This is commendable but it also makes sound financial sense. Whatever extra safety measures may cost the cost of an accident like total racking collapse is far worse and not fully covered by insurance. In certain situations like a large charity's warehouse responding to an emergency call, a total racking collapse would be unthinkable.

Trying to measure the immediate cost of a total pallet racking collapse is easy enough and will largely be covered by insurance but will the insurance pay out for the consequential costs like permanently lost business through failed timed deliveries. And if it can be shown that the management was negligent in a fatality any hefty fines would likely not be covered. Moreover, future insurance premiums would soar. "Insurance companies would look to the bare minimum and challenge continuation costs," added Craig. But with a Rhino system in place warehouse operators could expect noticeable insurance premium reductions given that total stock loss has been eliminated and therefore this should be reflected against risk.  

UK fatal racking collapses are rare, about one a month, but serious injuries are measured in their hundreds and there is at least one major rack collapse every week. The main causes or rack collapses can be summarized as: 1) Inadequate design, 2) Incorrect installation, 3) Overloading at pallet locations, 4) Damage, 5) MHE impacts, 6) Supporting floor failure, 7) Environmental or chemical deterioration, 8) Change of configuration away from which the racking was originally designed, 9) Poor weight distribution on pallets or pallet failures. There is a 10th but that only applies in earthquake-prone zones. 

Good advice on all the angles of racking safety can be had from the UK's Storage & Equipment Manufacturers' Association (SEMA) and HSE. 

*Rack Collapse Prevention Ltd. www.rcpsystem.com 

Rhino at Kybotech gives far more than peace of mind