Racking Inspection Training: The Basics

Importance

Before goods are released for transport, they’re first kept in the warehouse. Pallet racks are commonly used as they’re a multi-level storage solution for hauling goods around. However, they pose a significant hazard to the untrained eye. 

Racking inspection training ensures that pallet rack systems are well-maintained to avoid damaging stored products. It’s an integral component of warehouse safety training, yielding several benefits such as the following: 

• reduces hazards on-site; 
• protects workers from injuries; and 
• ensures the smooth flow of daily operations. 

Leading Causes of Unsafe Pallet Rack Systems

Before delving into the guidelines on handling and storage, it’s essential to identify the top causes of unsafe pallet racking to emphasize the importance of training. 

Causes of Unsafe Pallet Rack Systems

Understanding what makes a pallet rack system dangerous is key to instilling awareness among the team. Learn the top five causes below:

1. Forklift damage

Pallet racks go hand-in-hand with forklifts. Despite being the perfect combo for improving workflow efficiency, the problem arises when the truck crashes into the base of the pallet rack, weakening the structure and reducing its load-carrying capacity. 

To avoid this, it’s also vital to invest in forklift training. Ensure operators know the basics of load handling, maintenance, and maneuvering.

2. Unbalanced pallets

Improper installation of pallets is a recipe for warehouse disaster. This threatens workers’ safety and induces costly repairs. Unbalanced shelving destabilizes the rack’s overall structure and causes pallets to drop to the floor. Ensure equipment is stacked properly to avoid creating unnecessary problems for the crew. 

3. Overloading

Loading excessive amounts onto a pallet rack compromises its structure and puts stored goods at risk. Traditionally, a pallet rack’s load capacity is set at 2,000 pounds. To avoid potential collapse, make sure to follow the weight limit. 

4. Poor maintenance

If there are signs of corroded or damaged elements, don’t ignore them. To verify they’re kept in good working condition, OSHA and HSE recommend conducting racking inspections at least once every 12 months. 

Nonetheless, administering a routine maintenance schedule is an effective way to eliminate hazards and bring down warehouse expenses in the long run. Start by incorporating digitized tools to simplify pallet racking inspections. 

Create your own online racking inspection training checklist. Build from scratch or choose from our collection of free, ready-to-download, and customizable templates. 

5. Inadequate training

It’s important to note that the four causes mentioned above all stem from human action. Aside from educating employees on how to operate forklifts properly, rack inspection training ensures that every employee brings their a-game to work. It boosts their confidence and ensures smooth operations every day.

According to OSHA general standards, workers handling and storing materials must take note of the following guidelines on rack and forklift safety:

• 1910.176(a) – This discusses the use of mechanical equipment. OSHA requires sufficient safe clearances in aisles, loading docks, and doorways. These areas must be cleared and well-maintained, avoiding obstructions that could create potential hazards. Proper marking must be done for permanent aisles and passageways.
• 1910.176(b) –  This covers the proper storage of materials to avoid potential hazards. Bags, bundles, containers, and other items stored in tiers should be stacked, interlocked, blocked, and limited in height to keep them stable and secure, with minimal chances of sliding and collapsing. 
• 1910.176(c) – This standard discusses the housekeeping of storage areas. They must be free from the buildup of materials that may give rise to hazards, like tripping, explosion, fire, or pest harborage.

Tips to Implement an Effective Racking Inspection Training Program

Part of warehouse safety involves educating new and existing employees on the basics of pallet rack inspection. Note that guidelines may vary based on your country. For example, the United States’ OSHA has released guidelines on the proper storage of materials. Companies that fail to comply with its standards may incur violations and hefty fines. Meanwhile, the United Kingdom relies on the HSE for regulation. It recommends annual racking inspections by Storage Equipment Manufacturers’ Association (SEMA)-approved inspectors to match industry standards.

In general, here are four tips for an effective racking inspection training program:

• Document inspections – Present a checklist when conducting pallet racking inspections. Record keeping ensures the criteria for evaluation remain consistent and thorough. Also include dates, findings, and note potential repairs or replacements. 
• Promote training – Highlight the need for warehouse employees to undergo training, so they can spot initial signs of wear and tear. This will prevent complacency and overreliance on the racking inspector. Remember to establish clear guidelines for reporting.
• Conduct post-incident inspections – Prevent big issues before they happen. Minor forklift contact shouldn’t be ignored, as damage to the pallet rack system doesn’t always show up instantly. 
• Assign responsibilities – Delegate the responsibility of conducting regular inspections among workers and ensure corrective actions are in place. 

While investing in proper racking inspection training is key to the business’s success, this doesn’t have to disrupt the company’s established workflows. Mobile platforms like SafetyCulture’s Training are perfect for teams on the go with little time to spare each day. Lessons are delivered in bite-sized chunks to ensure maximum absorption and better knowledge retention.

Choose from an extensive library of over 1,000 courses, packed with 80+ pre-built templates to jumpstart your rack inspection training courses. No coding or professional design experience is needed.