Racking | Concrete Columns | On the Spot Engineering

RACKING REPAIRS \|\|\| MAINTAINING CONCRETE FLOORS \|\|\| MAINTAINING CONCRETE COLUMNS
*RACKING REPAIRS* INTRODUCTION Racking is a critical element in the warehouse distribution function and occupies more free space in warehouses than any other item of equipment. Without racking,warehouse business as we know it today would not exist. Consequently racking needs special attention and specialised techniques in ensuring the equipment is always maintained in a safe and functional condition. WHAT IS A RACK A rack in principle is a space frame built of relatively flimsy material. Its strength and ability to carry substantial loads lies in its assembled design. Its safety lies in ensuring its assembled integrity is maintained. Both continued strength and integrity are achieved by not abusing the racking and through good and regular maintenance. DAMAGE TO RACKS Because of their light structure racks are prone to damage. Common causes and effects are: BENT BEAMS: Reach truck operators turning with raised loads; Reach truck operators working in aisles with carriage extended; Reach truck operators reversing into beams; Reach truck operators misjudging entry height; Reach truck operators not paying attention to rear swing. SQUASHED AND TWISTED FRAME LEGS: Pallet truck operators using frame legs to push pallets onto forks; Pallet truck operators forcing pallets into tight slots (pallets skew or poorly positioned); Pallet truck operators striking bottom of legs with forks and foot plates; Pallet truck operators striking bottom of legs with protruding pallet sin passing. BUCKLED FRAMES: Reach truck operators hooking frames with loaded pallets while traveling down aisles; Reach truck operators reversing and turning out of racks before forks have cleared frames. PRINCIPLES OF RACK REPAIRS: 1ST PRINCIPLE - Critically damaged frames and beams must be replaced and not repaired. 2ND PRINCIPLE - Severely damaged frames and beams can be repaired, discretion is required. 3RD PRINCIPLE - Lightly damaged frames and beams require minor or no repairs. 4TH PRINCIPLE - Repaired beams are identified and used at low levels. 5TH PRINCIPLE - If in doubt, take it out STAYING ALIVE Racking should be inspected regularly. All damage should be listed. Causes of damaged should be identified. Critical and severe damage should be attended to urgently. Medium / minor damage should be monitored. Prevent damage through training and discipline. Physically protect racking with barriers and bumpers. Stick to the racking BOP. Click on the Gallery below to view larger images.



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*MAINTAINING CONCRETE FLOORS* WAREHOUSE AND EXTERNAL APRONS New Floors Specifications, Operating conditions, Hardness levels, Surface hardeners, Expansion joints: Primary & Secondary Design considerations Operational Duty requirements. Wheel loads: Types of wheels - Steel, Eurethane, Rubber, Solid, Pneumatic Operating Temperature Conditions Ambient, Cold Room, Sub zero THE WEATHER Daily temperature differential - Sun, Rain, Sleet, Snow OTHER FACTORS - Chemical cleaning agents, Vinegar, Sugar, Preservatives, Wine and spirits, Battery acids and alkalines, Diesel and oil. TYPICAL PROBLEMS INTERNAL FLOORS: Spalling of linear joints, Spalling of cross joints, Slab shrinkage, Slab tilt (rocking joints), Surface delaminations, Edge crumbling, Impact damage, Chemical corrosion. EXTERNAL APRONS Spalling of linear joints, Spalling of cross joints, Slab shrinkage, Joint sealer failure, Slab tilt (rocking joints), Impact damage, Edge crumbling, Water erosion, Temperature stress, Petroleum products. SUB ZERO FLOORS Thermal shock = delamination at door threshold, Impact damage, Spalling of linear and cross joints, Joint sealer failure, Water / ice damage. FLOOR REPAIRS Identify areas needing repair; Attend to repair at earliest opportunity; Use well known products in the trade; Use reputable contractors; Identify causes of damage; Implement measures to prevent re-occurrences. FLOOR CARE Inspect floors regularly; Clean at least once a week using a detergent; Mop up all liquid spills immediately; Neutralise acid and alkaline spills with plenty of water; Sweep up dry product spills immediately; Clean under the stock in the pick faces; Clean behind the barriers; Clean up diesel and oil spills immediately. Use a degreaser; Educate staff on hazards to floors and floor care. Click on the Gallery below to view larger images.


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*MAINTAINING CONCRETE COLUMNS* WHAT IS A CONCRETE COLUMN? A concrete column is a space frame of steel reinforcing around and within which is cast high strength concrete. Its strength and ability to carry substantial loads lies in its integral design of cured concrete and steel. Its safety is ensured by maintaining its design integrity. Strength and safety are achieved by ensuring there is no reduction in ratio between steel and concrete and that the column is not abused. Damage To Concrete Columns Common causes and effects are: Reach truck operators turning with loads and striking rack legs and columns. Reach truck operators turning in aisles with carriage and forks extended. Reach truck operators reversing into rack legs and columns. Reach truck operators not paying attention to rear swing and striking rack legs and columns. Pallet truck operators forcing pallets into tight slots (pallets skew or poorly positioned). Pallet truck operators striking bottom of rack legs and columns with forks and foot plates. Pallet truck operators striking bottom of rack legs and columns with protruding pallets in passing. PRINCIPLES OF COLUMN PROTECTION Direct Impact Restraint Principle Protectors bolted to floor to prevent direct contact with rack leg or concrete column. Protector separated from rack leg or concrete column by minimum 30mm to prevent "knock-on" effect of the force striking the barrier being transmitted directly onto the rack leg or concrete column. Protector separated from rack leg but using rack leg bolts to secure the protector to the concrete floor. Advantages: Protects the rack legs and concrete columns. No denting or chipping occurs. Disadvantages: Severe impact shears the bolts off. New holes have to be drilled resulting in "bolt-rash". After repeated drilling concrete is weakened. *IMPACT ABSORPTION PRINCIPLE* Advantages: Protects the rack legs and concrete columns, No denting or chipping occurs. The protectors are not bolted to the concrete; The protectors are more shock absorbent. The protectors are easily fitted; The protectors are easily removed and refitted. Disadvantages: Really severe impact will still be transmitted to the rack leg or concrete column. RACK LEG PROTECTORS




THE FIRST TRAIL Results: The protector shows signs of repeated impact. The protector shows no sign of damage (except paint scuff) The rack leg shows no normal signs of denting or squashing. The rack leg remains intact. MAKING THE RACK LEG PROTECTORS
New rack leg protectors in the making Steelwork: 5mm plate x 120mm wide x 80mm deep x 700mm long. 2 x 10 bolts x 6mm long with 11 flat washers and 10mm nyloc nuts
The high density foam in flat sheets and cut into strips High density epdm foam rubber: 1 x 25mm thick x 120mm wide x 700mm long. 2 x 25mm thick x 55mm wide x 700mm long.

OLD TYPE CONCRETE COLUMN PROTECTORS

Old type column protector showing two halves and strengthening gussets Results: effectively prevent damage to concrete columns, difficult to mark-off and drill holding down bolts. Difficult to bolt down and fit halves together. Expensive.
Inside of protector showing gussets and bolting technique.

MAKING THE COLUMN PROTECTORS


*NEW TYPE CONCRETE COLUMN PROTECTORS* The impact absorbing rack leg and concrete column protector is a practical and cost effective method of protecting those critical load bearing supports in our Distribution Centres		The new type Impact Absorbing Column Protector
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WHAT IS A CONCRETE COLUMN?