14. Pallet shelves

Permission and / or authorisation

  • All users of the storage facility and equipment (shelving units) must have received special theoretical and practical training.
  • The Plant Heads/Managers will establish, disseminate and maintain a list of persons qualified and authorised to remain in the shelving unit storage facilities.
  • The line of command will issue the cascading safety instructions.
  • The replacement and installation of elements on the shelving units will be done by authorised staff from the company supplying the storage equipment.
  • The Production Head and/or Supervisor of the section will ensure the safety of the storage equipment (shelving units) in their areas.

General provisions

  • The shelving units will have rating plates with real information on the facility in a visible place.

  • Any change, modification or extension made to the facility will first be studied and authorised by the storage system supplier (e.g., the supplier must be informed in the event of using Silestone pieces as crossbeams).
  • In places where work is being executed that entails a risk of falling objects,
  • Before carrying out any operation, the operator will evaluate the work conditions and consult their supervisors immediately if they have any doubts.
  • Always respect the maximum permitted loads and those established by the shelving unit supplier (See rating plate) and the load unit (pallet or container + goods).
  • Always respect the load diagram of the maintenance equipment (forklift). Pay attention to the permitted height depending on the weight and the distance from the centre of gravity of the forklift.
  • Perform a visual inspection on the state of the shelving unit, load unit and maintenance equipment. (Rule out any pallet in poor condition or unstable or non-compact load units, etc.)
  • Clear the area and make sure there are no people in the vicinity.
  • The external lateral racks will be extended at least 500mm above the last loading height and the internal ones will be extended 100mm.
  • Make sure that no unauthorised staff enter the storage areas.
  • The shelving units must have all the structural elements included in their design.
  • The concrete of the slab or framework on which the shelving unit will be installed must be at least type C20/25 (in accordance with EN1992) with a resistance of at least 20N/mm2.
  • The floor will have no areas that are sunken. They must be flat and have the appropriate resistance.
  • Check that all the corner braces located in passageways or at aisle intersections where vehicles could change direction have protective elements to prevent them from becoming deformed when hit.
  • The loads will be shrink-wrapped to prevent loose parts from falling.
  • When the safety profile is insufficient to prevent the goods from falling or a single shelving unit is adjacent to a work area or a passageway, safety nets will be installed.
  • When driving the forklift, the whole of the operator’s body must remain inside the vehicle. Never drive with your legs or arms outside the vehicle.
  • In operations that involve moving loads on shelving units, never stand below a suspended load or within the danger zone (area where the load could fall/overturn). The forklift operator or driver is responsible for enforcing this regulation. In addition, the operator must have perfect and permanent visibility while the loads are being loaded on/unloaded from the shelving units.
  • It is forbidden to place any element on the forklift roof that could block the operator’s view during the loading and unloading operations.
  • After completing the manoeuvre, the forklift will be placed in the appropriate marked area and the forks will always rest on the ground.
  • The heaviest loads must be stacked on the bottom shelves and the lightest ones on the top shelves.
  • It is forbidden to climb onto the shelving unit structure.
  • The entire base of the structures must rest on the ground and they will be braced together to ensure the verticality and stability of the unit.
  • The loads will be evenly distributed along the shelf to avoid overloading the structure on one side.
  • The shelves will only be used to store the load unit type (goods) indicated on the rating plate.

Most common pallet dimensions:

US Export Pallets: 1,217 x 1,017mm (SWL* 1,000kg)

Euro Export Pallets: 1,200 x 800mm (SWL 1,200kg)

Aus Export Pallets: 1,100 x 1.100mm (SWL 1,000kg)

UK Export Pallets: 1,200 x 1.000mm (SWL 1,000kg)

Asian Export Pallets: same as Aus..

  • Each shelving unit will be specially designed by the supplier for the type of material to be stored and have the necessary elements for that purpose (type and number of crosspieces, fastening supports/chocks in the case of materials that could move, etc.)
  • The pedestrian, work and vehicle aisles must be kept clean and clear of obstacles.

Safety in loading / unloading operations

  • It is mandatory to wear a helmet in all load lifting operations.
  • The load will be lowered and raised with the forks in a horizontal and centred position.
  • The load unit must not be centred in the opening by dragging it, but with the load suspended.
  • Ensure that the forks (and hoisting elements in general) do not become hooked to the package of material / pallet before removing them.
  • The pallet must always be centred between the support beams.
  • Respect the positioning clearances and tolerances.

Maintenance

  • The maintenance programme must include the facility where the storage equipment is kept (shelving units) and their accessory elements (forklifts, pallets, etc.), work areas (floor, aisles, signs, lighting, etc.).

This programme must include the following aspects among others

– Daily visual inspections by users.

– Monthly documented inspections by the warehouse managers.

– Inspections of all the storage equipment by specialised external firms. The frequency will depend on what is set out in the legislation and the supplier’s manual and on the frequency of use and experience in maintenance.

  • The Plant Heads/Managers will ensure that at least one annual inspection is performed by qualified external staff. A report will be written and delivered with the observations and proposals for actions to be taken (e.g. Mecalux).