Racking Collapse: How to manage the damage you don t see
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1 Racking Collapse: How to manage the damage you don t see Presented by: James Smith, Owner & Director Claire Porter, President PRESENTATION TITLE 2017 MHI Copyright claimed for audiovisual works and sound recordings of seminar sessions. All rights reserved.
2 Racking Collapse Customers & Collapse Consequences, Costs & Causes Inspection & Protection Detection & Prevention Prediction & Integration
3 CUSTOMERS & COLLAPSE
4 What do Customers Expect? Customers Expect 24hrs And they Won t Wait Logistics Essential to Stay Competitive Racking & Inventory Major Investments
5 RACKING PROTECTION: IS IT NEEDED?
6 Evacuation Hazardous PPE Fire Guarding Signage Emergency Light Racking Protection & Detection
7 Why is Racking Safety Important? Height 6ft Weight 190lbs Speed 3mph Height 7ft Weight 5500lbs Speed 8mph Height 30-50ft Weight 6500lbs Per Bay Weight 3300lbs Max Load Speed 0mph
8 Put them all together in a confined Space
9 Forklift Accident
10 Racking Collapse: 6 th May Hinstock Shrewsbury Miracle as forklift truck driver walks out of factory unhurt after being trapped under tons of CHEDDAR CHEESE for nine hours after massive shelving collapse
11 Racking Collapse: 6 th May Hinstock Shrewsbury
12 Racking Collapse Everybody just ran for their lives. The noise was deafening, it was like a sonic boom or an earthquake or something. I thought the whole place was going to come down and crush us all.
13 March 29 Manassas VA Andy Yobani Yoya-Rubio 21 (Left)
14 1 Worker Dead, 6 Injured Racking Collapse The support system for the beams started crushing, it started buckling and a domino effect all the way down the aisle, said Marcus Yates. Everything came down. "A couple of employees were crushed right in front of me. I saw it with my own eyes."
15 CAUSES, CONSEQUENCES & COSTS
16 Causes: Moving Vehicles, Static Objects Don t mix People, Moving Vehicles, machinery and static structures Creates High Risks Reduce or Eliminate the Risks
17 Causes: Potential Energy Potential Energy a function of Speed, Mass & Angle of Impact
18 Causes 2 Types of Impact: Catastrophic Cumulative
19 Guideline for the assessment and repair or Replacement of Damaged Rack Version Risks of Ignoring Damage The cost of rack collapses may far exceed the value of the entire rack structure and may lead to: Injury or loss of life Loss of product Loss of business and business interruption Large clean-up and replacement expenses Costly litigation
20 Consequences & Costs People Compensatio n Downtime Brand Reputation Vehicle Damage & Repair Racking Damage & Repair Rack Replacement Floor Damage & Repair
21 Costs What could racking collapse cost your business? $50,000 per day? $100,000 per day? $500,000 per day? What is the ultimate cost of collapse?
22 INSPECTION & PROTECTION
23 Inspection EN Nov Section P Racks must be inspected Regularly (Minimum Annual Inspection) Storage equipment shall be checked regularly for safety and specifically for any damage that has occurred. Records shall be maintained of all damage Responsible person. shall ensure that inspections are made at weekly or other regular intervals based on a risk assessment. A formal written record shall be maintained
24 EN Nov 2008 Deflection Not More than 3mm or.12 on Front of Leg Deflection Not More than 5mm or.2 on Side of the Leg
25 6.2 Inspection Considerations for the planning and use of Industrial Steel Storage Racks 2016 Edition The more prone the racks are to being damaged, the more often they should be inspected for damage. 1. Any reported damage should be inspected immediately 2. Racks with a high degree of damage potential should be inspected once a month 3. Racks with a medium damage potential should be inspected quarterly 4. Racks with a low damage potential should be inspected twice a year 5. All other rack systems should be inspected yearly
26 Guideline for the assessment and repair or Replacement of Damaged Rack Version Risks of Ignoring Damage When racks are damaged or improperly repaired, the load-carrying capacity of the structure may be reduced. Although a single instance of damage to the rack may not result in failure, severe or accumulated damage will reduce the capacity of the system and may ultimately lead to its collapse.
27 Inspections Employees Check Racking External Consultant Checks Racking Benefits Lower Cost Can be performed more frequently Benefits Expert Certification of Inspection Record of Inspection Disadvantages Less Expert Inspection must be recorded Ties up resources Disadvantages Higher Cost Disruption during inspection
28 Protection
29 Protection Steel Strong Available Potentially Lower initial investment Limited Impact Absorption Potentially Higher Maintenance Costs
30 Protection Polymer Potentially Higher Initial Investment Impact Absorbing Design 80% Force Dissipated Multiple Impact Product Potentially Lower Maintenance Costs
31 DETECTION & PREVENTION
32 Detection & Prevention What about the damage you don t see? Damage that is Un-reported? Damage that happens between Inspections? Reducing the instance of impacts?
33 Detection Catastrophic Cumulative Catastrophic: Obvious to Detect! Cumulative: Multiple low speed impacts Compromise the Structure over time
34 Cumulative: Detecting the Damage you don t see
35 Detection Technology an example
36 Detection Technology Solutions available What to look for Real Time Rack Monitoring 24 hrs / 365 days a year No Gap in Inspections Impacts Logged & Recorded Time & Date Stamps
37 Detection Technology: How it Works
38 Prevention Monitoring Can Promote Safer Driving Overcomes Un-reported Incidents Makes Drivers Aware of the Risks to their own Safety
39 INTEGRATION & PREDICTION
40 Integration: Combining Information Information is useless without integration Technology can now Link Devices, Smart Phones, Computers & Servers Racking can be managed by Zone Smartphones Add Photos, notes & Record Inspections Move from Paper to digital & off site storage
41 Integrating Impact Information Devices Detect Locate Alert Record Prevent To Monitor 24hrs 7 Days 365 Impacts Location Cumulati ve Damage Specific Location Where the damage is Instant Real- Time Info Location Impact Time- Stamp Data Reduce Risks
42 Prediction Each Incident Time Stamp Track & Traceability Historical Data Identify Hot-Spots Predict where impacts likely Specifically Target prevention / protection
43 Racking Collapse: Avoidable Collapse can be Catastrophic Collapse can be Expensive Collapse can be Fatal Collapse is Avoidable Collapse is Preventable
44 Avoiding Collapse 6 Strategies Protection Inspection Detection Prevention Integration Prediction
45 Thank you for your time
46 For More Information: Speaker Website: Speaker #2 website: Or visit ProMat Booth S1668
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