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MAINTENANCE STANDARD GUIDELINE ONTARIO OPERATIONS

TITLES

EQUIPMENT Steel Storage Racking Pallet Racking Selection and Installation

VALE

MGUID-82001

PAGE

of 16

DATED

2016-07-05

Version

1

Training Code (If applicable) n/a

Document Owner: Name: Dave Duczeminski Position: Maintenance Support Manager

Table of Contents

1. PURPOSE ........................................................................................................................................................................................ 2

2. SCOPE ............................................................................................................................................................................................. 2

2.1. Exceptions ............................................................................................................................................................................................. 2

3. REFERENCES ................................................................................................................................................................................. 3

4. DEFINITIONS ................................................................................................................................................................................... 4

5. PALLET RACKING ......................................................................................................................................................................... 6

5.1. Single Row or Double Row .................................................................................................................................................................. 6 5.2. Roll Formed vs. Structural Steel Selective Pallet Racks ................................................................................................................. 7 5.3. Typical Pallet Rack Components ........................................................................................................................................................ 7 5.4. Typical Protective Devices ................................................................................................................................................................... 7

6. SELECTION ..................................................................................................................................................................................... 8

6.1. Conducting a Needs Assessment ....................................................................................................................................................... 8 6.2. Creating a Purchase Specification...................................................................................................................................................... 9

6.2.1. Layout Drawings & Elevation Views ..................................................................................................................................... 10 6.2.2. Component Quality & Quantities ........................................................................................................................................... 10 6.2.3. Special Considerations ........................................................................................................................................................... 11 6.2.4. Owner & Vendor Responsibilities ......................................................................................................................................... 11

7. INSTALLATION ..............................................................................................................................................................................11

7.1. Manufacturer’s Documentation ......................................................................................................................................................... 11

8. PRE-START HEALTH AND SAFETY REVIEW (PSR) ................................................................................................................12

8.1. What is a PSR? ................................................................................................................................................................................... 12 8.2. When is a PSR Required? ................................................................................................................................................................. 12 8.3. PSR Exemption ................................................................................................................................................................................... 13

9. RECORD KEEPING .......................................................................................................................................................................14

9.1. Using SAP ............................................................................................................................................................................................ 14

10. APPENDICES .................................................................................................................................................................................15

Maintenance Standard Guideline

FOR INTERNAL USE of 16 Ver. 1

EQUIPMENT Steel Storage Racking

MGUID-82001 Pallet Racking Selection and Installation

1. PURPOSE

This guideline provides general information on the selection and installation of steel storage pallet racking. Because design and installation requirements may differ from plant to plant, it is always important to follow the manufacturer’s instructions/specifications. This guideline should be used in conjunction with the most recent revisions of the “References” listed in this document as they provide further guidance to, and information on, the applicable government regulations and standards related to steel storage racking safety practices and procedures.

2. SCOPE

This guideline makes reference primarily to selective pallet racking (single-row or double-row) made of steel that are typically constructed from cold rolled or hot rolled (structural) steel members; however, the principles set out in this guideline may be used when selecting and installing other types of racking such as cantilever, portable, and other forms of steel storage racking.

2.1. EXCEPTIONS

Storage racking is often found being used as shelving. This guideline is not applicable to this type of installation. Is it racking or shelving?

Storage unit in question

Are materials loaded or unloaded from the unit using material handling equipment?

i.e. Forklift

SHELF

PALLET RACK

NO

YES

Place signage to identify as shelving and restrict from material handling equipment unloading/loading

Work in compliance with OHSA regulations,

and CSA codes and guidelines

Ensure installation, inspection,

documentation, and usage in compliance with current OHSA regulations, MOL

regulations, and CSA codes and guidelines.

Work in compliance with OHSA regulations,

and CSA codes and guidelines.

Steel racking used strictly as shelving should have signage indicating that material handling equipment is not to be used to place or remove product or materials from the shelving unit. SAMPLE SIGNAGE





3. REFERENCES

The following references were used in the development of this document or are related to it. These references should be used in their most recent revision as they provide further guidance to the applicable government regulations and standards related to the steel storage racking safety practices and procedures.

Vale’s Golden Rules

Vale’s HomeSafe Program

Occupational Health & Safety Act and applicable regulations

Guidelines for Pre-Start Health and Safety Reviews: How to Apply Section 7 of the Reg. 851 - Regulation for Industrial Establishments

CAN/CSA A344.1 User Guide for steel storage racks / CSA 344.2 Standard for design and construction of steel storage racks

CSST Safety of Pallet Rack, Prevention Guide, Construction, purchase, installation and use, Commission de la santé et de la securite du travail du Quebec, 2005

CAN/CSA B334 – Standard for Lift-Truck Safety





4. DEFINITIONS

Anchor – a mechanical fastener used to secure a pallet rack structure to a building structure, e.g. the baseplate to the floor slab Back-to-back row – two parallel rows of pallet racks that are joined by one or more levels of row spacers between frames Beam (load beam) – a horizontal member, usually arranged in pairs such that the upper horizontal surfaces support pallets placed on them Baseplate (footplate) – a plate fixed (usually by welding) to the bottom of frame columns to facilitate anchoring to the floor slab and distributing the weight of the loaded column over a larger area of the floor slab – to give the rack more stability Beam connectors (beam brackets, end plates) – a formed, stamped part welded to each end of the beams to facilitate their attachment to the frames CSA – Canadian Standards Association ERP – Enterprise Resource Planning – a business process management software that allows an organization to use a system of integrated applications to manage the business Floor slab – any floor system, either on grade or otherwise, capable of supporting the rack loads Frame (end frame, upright frame) – an assembly of two vertical members (columns) and braces that is used to support the load beams Horizontal and diagonal braces – members generally welded between frame columns to resist cross-aisle forces imposed on frames and brace the columns Material Handling Equipment – lift trucks of all classes and other types of powered equipment used to directly or indirectly load and unload a pallet rack MoL – Ministry of Labour Pallet rack – a material handling storage aid system designed to store materials on pallets (or “skids”) Pallet support bar – a bar similar to a safety bar except a pallet support bar is intended to support the full weight of a loaded pallet in cases where size, strength, or style of pallet prohibits its placement directly onto a load beam Post guard (column guard, post protector) – a member or device designed to prevent accidental impact to the column member PSR or PHSR (Pre-Start Health and Safety Review) – a documented inspection report done by a knowledgeable person to determine if the systems/structures are safe to use and that contains recommendations on what to do if they are not. Legislated in Ontario, under Section 7 of Ontario’s Regulation for Industrial Establishment (O. Reg. 851), Clause 45 (b) Row end protector – typically, a structural member attached to or fixed to the floor slab adjacent to the ends of pallet rack rows or in tunnel bays to protect against impact by material handling equipment Row spacer (row connector) – a member used to connect two aligned frames, one behind the other, ensuring that while joined they remain separated by a specific distance





Safety bar – a member supported by and oriented perpendicular to load beams, intended to temporarily support misplaced pallets Safety pin (lock pin, safety clip) – a device or mechanical fastener used to prevent the accidental dislodgement of beam connectors from frames Selective pallet rack – a pallet rack arranged in one row or a series of rows such that every pallet loaded on the rack faces an aisle allowing direct access by material handling equipment Shelving – a structure consisting mainly of upright frames and load support beams to accommodate loads. Shelving is typically designated for light loads and is NOT used in conjunction with forklifts or other material handling equipment and should have signage affixed indicating “SHELVING - NO MATERIAL HANDLING EQUIPMENT TO BE USED TO LOAD OR UNLOAD” Single row – a row of pallet rack that is free standing, i.e. it is not joined to an adjacent rack row using row spacers Stored load – a maximum load of pallets and product stored on the racks Wire mesh screens – wire decking for pallet racks designed to provide the ability to store split case, open case and other smaller items which meet the load rating of the decking





5. PALLET RACKING

Pallet racking is a material handling storage system designed to store materials on pallets (or skids). They are meant for use in typical warehouse environments employing careful, well-trained material handling equipment operators handling stable, common pallet loads. The most common pallet racking formats allow for the storage of palletized materials in horizontal rows with multiple levels. Selective pallet racking is one form of pallet racking that provides easy accessibility to all products at all time. Selective pallet racking systems use uprights, bracing, beams and cross support bars to create a “shelf” for storing a pallet. Depending on the height of pallets and ceilings, pallet rack systems typically have multiple shelves (levels) per bay. A bay is typically only one pallet deep. Since loads are stored one pallet deep, this is the lowest density storage of any system, and it allows unimpeded access to every pallet. It can be used in a number of aisle configurations and can be paired with any type of lift truck.

5.1. SINGLE ROW OR DOUBLE ROW

There are two types of selective pallet racking: single row or back-to-back (double) row. Single rows, even though equal in capacity to back-to-back (double) rows, is more susceptible to overturning or collapse damage. The CSA encourages end users to consult with the supplier, so that the appropriate measures are put in place to lessen the chances of a collapse due to accidental impact. There are various methods that can be employed: post guarding, double-posting the aisle leg of the frame, heavy duty frame bracing, heavy duty baseplates and anchors, and cross-aisle top ties and/or wall connectors (appropriately designed and installed.)

B

Back-to-back (double) Row

Beam

Uprights

Frames

Support bar

Bracing

Safety pin

Pallet Racking Bay

Base Plate





5.2. ROLL FORMED VS. STRUCTURAL STEEL SELECTIVE PALLET RACKS

Selective pallet racking typically come in one of two configurations: roll formed or structural steel. Roll formed racking components are lighter, easily snap together and as a result are less expensive to buy and install; however, they are limited to the amount of weight that they can support and are more easily damaged by fork lift trucks. Structural steel components are made from heavier, cast steel and can provide higher load capacities. Since structural components are bolted together, they can take slightly more labour to install, however may require less maintenance. Structural steel typically costs more than roll-formed. For applications involving one or more of the following conditions, structural steel may be the best choice: tall selective rack structures (e.g. 25' or higher) and high traffic / damage-prone environments

5.3. TYPICAL PALLET RACK COMPONENTS

Frame

Horizontal and diagonal bracing

Beam

Beam connector

Row spacers (for double-row)

Base plate / footplate

Anchors

Anchor bolts

5.4. TYPICAL PROTECTIVE DEVICES

Column guards

Guard rails

Safety pins

Safety bars

Pallet support bars

Accessories for protection against falling objects

Compartment end stops





6. SELECTION

Pallet racking for material and products stored on pallets should be designed/selected specifically for the size, shape and weight of the materials and products to be stored. The racking should be aligned with the type of pallets and the material handling equipment to be used in the workplace. One important consideration that is often overlooked is the width of the aisles. Aisles should be wide enough to accommodate the turning circle of the forklift or material handling equipment used to load or unload the racks.

To reduce the risks related to racking hazards, take time to conduct a needs assessment to determine the specifications for the racking you require.

6.1. CONDUCTING A NEEDS ASSESSMENT

In order to prepare a purchase specification for a pallet rack system, you should qualify and quantify the following:

products and nature of products to be stored

the material handling equipment to be used

building characteristics in which the rack system is to be installed Other information to qualify and quantify:

load characteristic: weight, center of gravity, size (width, depth, height)

load support means: types of pallets, weight and size of pallets, pallet load capacity

inventory management methods

types of material handling equipment used

durability required

accessories and protective devices required

environmental conditions: humidity, pollution, corrosive agents

seismic hazards The building and its foundation are important factors to consider when selecting racking. The building in which the pallet racks will be installed has characteristics that must be taken into account:

square footage – all dimensions

location and size of any columns

mechanisms for heating, ventilation units

gas/water piping and water mains, electrical equipment

light fixtures, location of sprinklers and fire extinguishers

doorways and exits

permanent building fixtures/obstructions

clearances available around and above proposed racking structure

pedestrian walkways/passages, emergency egress, paths, aisles, other foot traffic The information gathered from the needs assessment will help you select the best pallet racking system – one that will deliver on expected performance and safety requirements.

Occupational Health and Safety Act, Reg 851, S. 45 (b)

Employer duty to ensure materials, articles or things are stored safely so workers are not endangered.





6.2. CREATING A PURCHASE SPECIFICATION

The following are methods for creating a purchase specification:

refer to specifications made from a previous purchase i.e. rack system purchases in the past that are similar to your requirements

refer to supplier Website/literature/brochures

recruit a consultant to assist with your racking layout and elevation requirements

solicit racking suppliers for proposals and quotes

The creation of an accurate specification for your pallet rack requirements will depend on the knowledge, skill and ability (competence) of the person completing your needs assessment.

If you are purchasing racking components, you should receive load rating information and documentation from the supplier indicating the structural steel grade and quality control information for the racking components. Some suppliers may also provide you with capacity labels; however, in some cases, they may not because the capacity may depend on other factors in your racking structure system and not just the capacity of the components you are purchasing. If you are purchasing a complete racking system, you should receive from the supplier/manufacturer:

Design drawings, stamped by a professional engineer which should:

o Indicate rate capacities (In Ontario, this is effectively a Pre-Start Health and Safety Review Exemption in accordance with Section 7 of OHSA Reg. 851)

o Show length, depth, height, row heights, connections to building or between structures

o Provide specifications of the upright frames and stringers and where each type is used (if reinforced frames are used, how high the reinforcement extends)

A statement to the effect that the system was designed to meet current regulations and standards If a third party is installing the components or the complete system, you should receive:

a letter from the installer stating that the installation was carried out in accordance with current regulations and standards

The following sections in this guideline provide an overview of the considerations you will need to make to specify your racking requirements.

The CSA A344.1-05 User guide for steel storage racks is intended for persons who create specifications for, purchase, and use, steel storage racks. In referencing this Guide, you will become aware of the considerations required to generate an effective pallet rack specification. The CSST Safety of Pallet Rack, Prevention Guide, Construction, Purchase, Installation and Use, Prevention Guide 2005 is aimed at inspectors and managers. It provides a “record form” that can be used to walk you through specifying your racking requirements so as to meet your needs in terms of use, safety and costs.





6.2.1. LAYOUT DRAWINGS & ELEVATION VIEWS

In order to ensure your pallet rack system is going to meet your needs and to help you prepare a purchase order, it would be helpful to create a layout and elevation drawing of your required racking system. Create a layout (general arrangement) of the racking rows and aisles required including spacing dimensions. Remember, aisles need to be wide enough for material handling equipment to enter and exit safely. Create a front and side elevation for each different bay configuration you will require to accommodate pallets and materials to be stored. SAMPLE LAYOUT DRAWING SAMPLE FRONT/SIDE ELEVATION VIEWS

Elevation views should identify your load rating requirements, pallet storage capacity, and configurations needed to meet requirements of material handling equipment to be used. The height and depth of racking must be considered within the building structure to ensure you have sufficient clearance above and within the racking structure to accommodate the handling of material as well as other requirements such as lighting fixtures, sprinkler systems etc.

6.2.2. COMPONENT QUALITY & QUANTITIES

Once you have a layout and elevation drawing, and know the sizes and capacities for loading you will require, the quantities of each racking component required will be easy to determine. (Consider frames, beams, row spacers, safety bars etc.) The quantities and types of protective devices you will require should also be specified. Consider that racking damage is most often found to occur in the lower portions of racking structures – mostly caused by the movement of material handling equipment. Consult with your racking supplier to ensure you select the best options to protect this area of your racking structure. Components can be selected by referencing a suppliers/manufacturer’s brochures for these components and their load rating charts or by having the supplier provide you with a bill of materials based on your defined requirements. You can also request several vendors to submit proposals that you can then review and select from.

)





6.2.3. SPECIAL CONSIDERATIONS

Racking suppliers should be made aware of any special considerations or applications related to your workplace. Your racking structure may need to be altered to satisfy any special intended uses or conditions related to your workplace. The following are some examples:

Racking in high seismic zones

Requirement for the installation of in-rack sprinklers along with defined clearances for sprinkler equipment

Storage of hazardous or toxic materials

6.2.4. OWNER & VENDOR RESPONSIBILITIES

Contractual agreements for purchase of racking can be complex. Contact your assigned Vale buyer for direction and guidance in this area. It is important for both the purchaser and vendor to have a competent person responsible for the purchasing project to ensure clarity of intention between them.

7. INSTALLATION

The Canadian Standards Association recommends that the installation of steel storage racking structures is best delegated to competent personnel who are regularly employed in erecting racking i.e. the manufacturer, one of the manufacturer’s representatives, or experts in the field of racking installation.

Competent personnel will install racks according to the drawings and manufacturer’s specifications and will ensure the following:

the rack assembly is perfectly vertical, perfectly level, and square

all connections, locks, and anchors are secure to ensure the structural integrity of the racking and safety of anyone in the vicinity of the racking

manufacturer’s rack specifications and documentation confirming compliance with current standards and regulations are provided to you

Any deviations during installation from the drawings or manufacturer’s specifications must be approved by the designer or a Professional Engineer and noted on the as-built drawings.

7.1. MANUFACTURER’S DOCUMENTATION

You can expect the following information from the racking supplier. Consider including these requirements in your tender documents/purchase orders:

Racking Layout and Elevation Drawings

Manufacturer’s Specifications/Instructions

Documentation confirming that the racking was designed and tested in accordance with current applicable standards. If this documentation is not provided, you may be required to conduct a Pre-Start Health and Safety Review.





8. PRE-START HEALTH AND SAFETY REVIEW (PSR)

If you are installing new steel storage racks, you need to determine whether you will need to conduct a Pre-Start Health and Safety Review (PSR).

As per CSA A344.2, manufacturers are required to maintain records. These documents may be required by the Ministry of Labour (MOL) at the time of facility inspections. Employers should:

Obtain the documentation from the manufacturer that indicates the rack was designed and installed in accordance with current applicable standard and manufacturer’s specifications, or

Have a Pre-Start Health and Safety Review

Ontario Health and Safety Act & Regulation 851 requires that a PSR be conducted if the required documentation from the manufacturer is not available. The rack manufacturer or a Professional Engineer may be consulted for the PSR. A PSR is also required if alterations to the manufacturer’s specifications have been made or if the rack has undergone major repairs or has been relocated and there are changes to the parameters to which it was designed.

If the installed racking and its protective elements were designed and installed according to current applicable standards and the supplier has provided documentation stating the racking structure was designed and tested for use in accordance with current applicable regulations and standards, a PSR may not be required.

8.1. WHAT IS A PSR?

A PSR is a written report on the construction, addition or installation of a new apparatus, structure, protective element or process, or modifications to an existing apparatus, structure, protective element or process. The report details the measures necessary to bring the construction, addition, installation or modification of structures into compliance with the applicable provisions of the Regulation for Industrial Establishments as outlined in Section 7 of the regulation. The intent of this review is to ensure:

a timely professional review identifies specific hazards

hazards are removed or controlled before the racking structure is used

worker protection as required under the applicable provisions of OHSA, Reg. 851

8.2. WHEN IS A PSR REQUIRED?

A PSR would be required when the plant:

Installs a new racking system

Modifies or reconfigures an existing racking system

Employers should determine whether they need to conduct a Pre-Start Health and Safety Review. [OHSA, Reg. 851, section 7] The Guideline for Pre-Start Health and Safety Reviews: How to Apply Section 7 of the Regulation for Industrial Establishments provides information on the levels of diligence, methodology and reporting required to comply with Section 7 of the Regulation for Industrial Establishments and should be referenced.





Depending on certain regulatory criteria, a PSR may or may not be required. Examples:

1. If racking was designed and installed according to current applicable standards and the supplier has provided documentation stating the racking structure was designed and tested for use in accordance with current applicable regulations and standards, a PSR is not required.

2. For repair or modification using a part from the original rack manufacture, if the repair follows current applicable regulations and standards, a PSR not required.

3. For modification or reconfiguration of racking that is not recorded on the documentation provided by the original rack manufacturer and does not follow current applicable regulations and standards, a PSR is required.

If a PSR is required, the facility Manager shall ensure that the racking is not used until the review has been conducted and all measures identified in the review as being required for compliance with the relevant regulatory requirements are implemented.

8.3. PSR EXEMPTION

According to regulation, the following documents are acceptable to establish an exemption: 1. A notice in writing from both:

a. the manufacturer declaring that the apparatus and protective element have been manufactured or modified to meet current applicable standards

b. the installer stating that the apparatus and protective element were installed in accordance with the manufacturer’s instructions and current applicable standard, if applicable

2. And, if protective elements were not installed when the apparatus was manufactured, a notice in writing from the installer stating that the protective elements were installed in accordance with the manufacturer’s instructions and current application standards

The plant shall keep documents establishing the exemption readily accessible in the workplace for as long as the racking structure and protective elements remain in the workplace. A copy of the exemption documentation is to be submitted to the Joint Health and Safety Committee before the racking is used.

The OHSA, Reg. 851 Section 7 of the Regulation for Industrial Establishments, April 2001 stipulates that the facility shall keep documents establishing regulatory compliance for installed structures (i.e. racking) readily accessible in the workplace for as long as the racking structure and protective elements remain in the workplace. A copy of this documentation is to be provided to the workplace’s Joint Health and Safety Committee before the racking is used.

A PSR is not required when the employer has documentation showing that the rack has been designed and tested in accordance with the current applicable standards [Reg. 851, subsection 7(7)].





9. RECORD KEEPING

The plant shall maintain the following documentation in a safe and easy to access location available to JHSC members and inspectors:

Original racking layout and elevation drawings

Current racking layout and elevations drawings (containing any changes to original documents)

Manufacturer’s Instructions/Specifications

Documentation from the manufacturer that indicates that the rack was designed and installed in accordance with current applicable standards and manufacturer’s specifications, and/or any Pre-Start Health and Safety Review Reports

Documentation on inspections, damage reporting, SAP IM Reports, and all maintenance work

9.1. USING SAP

SAP is Vale’s Enterprise Resource System (ERP). As it relates to steel storage pallet racking systems, SAP can provide the following functionality for those responsible for steel storage racking systems, their maintenance and inspection:

Work Order/Requisition – to record supplier and all procurement details related to the materials, quantities, quality and installation requirements

Record of the asset – to maintain details of the racking: description, physical location and function within the plant’s process/equipment hierarchy

Document repository – to hold PDF copies of drawings, specifications, inspection reports, and documents indicating regulatory compliance etc.

Maintenance plan – to describe dates and scopes for regular legislated inspections

Work management system – to record and monitor the planning, scheduling and execution of maintenance work required to maintain the racks in good condition, safe to use

Incident management reporting system – to record incidents, investigation, analysis and the corrective actions implemented to maintain rack stability and integrity

For more information or assistance in utilizing the above SAP functions consult with your plant’s SAP Divisional Support.

Applicable regulations:

Employer duty to provide an engineer’s report on load limits for structures. [OHSA S. 54 (1) (m)]

Employer duty to provide any drawings, specification, document, record or report [OHSA S. 54 (1) (c)]





10. APPENDICES

APPENDIX A: Revision Notes and Approvals





Appendix A: Revision Notes and Approvals The Revision Notes and Approvals table only displays the latest revision number and a list of the last revisions made to the document. For details on previous revisions contact the document owner.

Rev Revision Notes

1

New guideline

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