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.
Racking Collapse Customers & Collapse Consequences, Costs & Causes Inspection & Protection Detection & Prevention Prediction & Integration
CUSTOMERS & COLLAPSE
What do Customers Expect? Customers Expect 24hrs And they Won t Wait Logistics Essential to Stay Competitive Racking & Inventory Major Investments
RACKING PROTECTION: IS IT NEEDED?
Evacuation Hazardous PPE Fire Guarding Signage Emergency Light Racking Protection & Detection
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
Put them all together in a confined Space
Forklift Accident
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
Racking Collapse: 6 th May Hinstock Shrewsbury
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.
March 29 Manassas VA Andy Yobani Yoya-Rubio 21 (Left)
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."
CAUSES, CONSEQUENCES & COSTS
Causes: Moving Vehicles, Static Objects Don t mix People, Moving Vehicles, machinery and static structures Creates High Risks Reduce or Eliminate the Risks
Causes: Potential Energy Potential Energy a function of Speed, Mass & Angle of Impact
Causes 2 Types of Impact: Catastrophic Cumulative
Guideline for the assessment and repair or Replacement of Damaged Rack Version 1.00 4. 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
Consequences & Costs People Compensatio n Downtime Brand Reputation Vehicle Damage & Repair Racking Damage & Repair Rack Replacement Floor Damage & Repair
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?
INSPECTION & PROTECTION
Inspection EN 15635 Nov 2008 9.2 Section P Racks must be inspected Regularly (Minimum Annual Inspection) 9.4.1 Storage equipment shall be checked regularly for safety and specifically for any damage that has occurred. Records shall be maintained of all damage 9.4.2.2 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
EN 15635 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
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
Guideline for the assessment and repair or Replacement of Damaged Rack Version 1.00 4. 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.
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
Protection
Protection Steel Strong Available Potentially Lower initial investment Limited Impact Absorption Potentially Higher Maintenance Costs
Protection Polymer Potentially Higher Initial Investment Impact Absorbing Design 80% Force Dissipated Multiple Impact Product Potentially Lower Maintenance Costs
DETECTION & PREVENTION
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?
Detection Catastrophic Cumulative Catastrophic: Obvious to Detect! Cumulative: Multiple low speed impacts Compromise the Structure over time
Cumulative: Detecting the Damage you don t see
Detection Technology an example
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
Detection Technology: How it Works
Prevention Monitoring Can Promote Safer Driving Overcomes Un-reported Incidents Makes Drivers Aware of the Risks to their own Safety
INTEGRATION & PREDICTION
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
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
Prediction Each Incident Time Stamp Track & Traceability Historical Data Identify Hot-Spots Predict where impacts likely Specifically Target prevention / protection
Racking Collapse: Avoidable Collapse can be Catastrophic Collapse can be Expensive Collapse can be Fatal Collapse is Avoidable Collapse is Preventable
Avoiding Collapse 6 Strategies Protection Inspection Detection Prevention Integration Prediction
Thank you for your time
For More Information: Speaker email: Claire.Porter@asafe.com Website: www.asafe.com Speaker #2 email: James.Smith@asafe.com website: www.asafe.com Or visit ProMat Booth S1668