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Pallet racks are commonly found in warehouses, distribution centres, retail operations, and manufacturing plants. Usually made of steel, pallet racks often support heavy loads which may collapse if improperly installed or used. This can lead to serious injuries or death for workers. During a recent five year timeframe, three workers died and 45 others received serious injuries involving racking and storage. Ref – Ontario workplace statistics.

Examples of safety issues involving racking and storage include:

• poor storage rack design;
• incorrect installation and assembly of racking system;
• structural problems with the floors or walls of the storage area such as uneven floors and overloaded supporting structures;
• concrete floors with cracks and breaks around the racking unit anchors resulting in racking that is not level;
• poor/inadequate storage rack maintenance and repair;
• incorrect use of racking or overloading;
• lack of regular inspection and maintenance program; and,
• products sticking out the back of the racking.

Deficiencies can lead to:

• partial or total failure/collapse of racking systems;
• forklifts colliding with racks causing material to be displaced or causing potential damage to the racking itself; and
• material falling through the back of the racks.

Metal storage racking found in DND are typically an original install during building construction or shortly thereafter. The framework is usually made of steel, cold-formed or structural shapes.

They are usually organized in horizontal rows with multiple levels and used to store large and heavy items such as pallets and skids. They could also be used to store vehicle or aircraft parts, rations, heaters, barbed wire, hand tools, chainsaws, stoves, etc. The Chain of Command (CoC) can typically research the brand of storage racks based on their design which provides them with valuable information for installation, maintenance, connectors, protective equipment or replacement parts. Replacement equipment can usually be purchased through approved suppliers found on the National Master Standing Offers (NMSOs).

Inspection Priorities: Monthly workplace inspections shall focus on the following key priorities: Installation and Selection: Inspectors shall check that racking and storage systems have been selected and installed to ensure the safety of workers and the material being stored.

Condition, Maintenance and Repair: Inspectors will check that racking and storage systems are properly maintained and repaired.

Use of Racks: Inspectors will check that lift trucks are being driven and products are being loaded and unloaded on pallet racks in a safe manner.

Forklift Activity: Inspectors will check that appropriate lift trucks are being used for the workplace and tasks required. This includes; checking that the trucks’ capacity is sufficient to carry the required loads, that Narrow Isle Lift-trucks are being used for narrow aisles and that operators have the appropriate training.

Other Related Issues: Inspectors will check that aisles are free of obstructions, lighting is adequate, pallets are in good condition, racking is designed for sprinklers (where required) and back to back racking is secured together.

Training: In 2016, 2 CMBG along with Garrison Petawawa Safety Service’s and a Safe Work Association conducted a one day Metal Storage Rack Inspection course. This course included both theory and practical exercises in an effort to better inform both military and civilian personnel of their overall responsibilities with respect to Metal Storage Racks within their workplaces. If Garrison or Lodger units wish to pursue further training opportunities, please contact 4 CDSB Safety Services.