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Summary of Contents for Dexion DEEPSTOR DEIVE-IN PALLET RACKING
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Page 1: User Instructions
DEEPSTOR DRIVE-IN PALLET RACKING USER INSTRUCTIONS... - Page 2 BLANK...
- Page 3 DRIVE-IN PALLET RACKING USER INSTRUCTIONS This manual remains the sole property of Dexion (Australia) Pty Limited. It must not be copied without prior written consent and must be returned upon request. The information contained within this guide relates solely to the Dexion product, it doesn’t...
- Page 4 MANUAL AMENDMENT REGISTER DEEPSTOR USER INSTRUCTIONS Issue / Date Description Amendment Issued Issue 1 Aug 03 Original Issue. ISSUE 1 AUGUST 2003 Deepstor User Instructions Inserted Page iv...
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Page 5: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ...1 OPERATOR TRAINING ... 1 INSTALLATION DATA SHEET ... 2 GLOSSARY OF DEXION TERMINOLOGY... 4 THE PALLET ...5 PALLET TYPE AND SIZE ... 5 IMPORTANT NOTES:... 5 LOAD ON THE PALLET... 5 PALLET WEIGHT ... 6 PALLET CONDITION... - Page 6 DAMAGE INSPECTION – FRAMES ... 26 DAMAGE INSPECTION – RACK OUT-OF-PLUMB ... 27 RISK ASSESSMENT...28 GREEN RISK ... 28 ORANGE RISK ... 28 RED RISK ... 28 DAMAGE ACTION PROCEDURE FLOWCHART ... 29 TYPICAL CAUSES OF DAMAGE ... 30 PRECAUTIONS AGAINST DAMAGE ... 30 ISSUE 1 AUGUST 2003 Table of Contents...
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Page 7: Introduction
The guide does not go into the specifics of individual installations. OPERATOR TRAINING Dexion recommends that ALL personnel operating within a warehouse environment are trained in safe working practises. Part of the training given to fork lift truck drivers should include the correct use of the Deepstor installation. -
Page 8: Installation Data Sheet
INSTALLATION DATA SHEET Your installation has been designed around a pallet with the following characteristics. Client: Date of Installation: Dexion reference: Block Ref. or Rack Area: Pallet Type: Pallet size: Pallet handled on the: Load size (left to right) Load size (front to back) Any load overhang must be even on both sides. -
Page 9: Installation
Deepstor User Instructions To ensure safe use of the storage equipment, the user must understand the following points: Use of the equipment The installation must be used in accordance with the specification and the criteria used for the design of the rack. The duty of the rack components will have been specifically selected to meet the individual load requirements of each rack. -
Page 10: Glossary Of Dexion Terminology
GLOSSARY OF DEXION TERMINOLOGY The following terms are referred to within this guide. Rack/Block: The complete structure, in length, depth and height, consisting all lanes and levels from the front of the rack to the back. Lane: A proportion of the rack separated by support frames includes all levels in the height. -
Page 11: The Pallet
THE PALLET The following gives general information about the pallet. PALLET TYPE AND SIZE Your Deepstor rack will have been designed around a specific pallet style and dimensions, this will be detailed within “The Installation Data Sheet” on page 2. The most common and widely used industrial pallets have also been illustrated on the following page to aid identification. -
Page 12: Pallet Weight
The load must be distributed across the whole area of the pallet to avoid any potential uneven loading of the rack. Do not enter pallets with weights that exceed the permitted limit as indicated on the Dexion Load Signs. PALLET CONDITION Pallets must be in good condition, and free from damage. -
Page 13: Pallet Illustration
PALLET ILLUSTRATION Australian Chep Wooden Pallet (1165x1165x145) Pallet Self Weight: 40Kg Timber: Hardwood. The Australian standard pallet has a square base of 1165mm (W) x 1165mm (D) with a maximum height (H) of 150mm. The minimum clear entry height between bearers is 90mm. The pallet is a 2- way entry pallet. - Page 14 Deepstor User Instructions User Instruction ISSUE 1 Page 8 AUGUST 2003...
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Page 15: The Fork Lift Truck (Flt)
Deepstor User Instructions THE FORK LIFT TRUCK (FLT) The fork lift truck must be of a suitable design and capacity, capable of lifting the loads to the heights required. If there are any doubts regarding its capacity reference should be made to the relevant manufacturer or supplier. -
Page 16: Operational Clearances
Deepstor User Instructions OPERATIONAL CLEARANCES LOAD ON THE PALLET The load should be stacked centrally on the pallet, and if overhang has been permitted within the design, the overhang should be even on both sides of the pallet. LOAD WITHIN THE LANE The fork lift truck should deliver the pallet squarely and centrally within the storage lane. -
Page 17: Flt Clearance
Deepstor User Instructions FLT CLEARANCE To minimize unnecessary forces induced on the rack by a forklift truck during its operation, it is essential that a minimum clearance of 75mm on either side of the widest part of the truck and arm/rail projection be provided. -
Page 18: Loading / Unloading The System
Deepstor User Instructions LOADING / UNLOADING THE SYSTEM The warehouse should be adequately lit, to permit the safe use of forklift trucks and the handling of pallets. PICKING UP THE PALLET The pallet must be picked up square to the forks, any misalignment of the pallet on the forks can’t be corrected during the placement sequence and results in badly placed pallets within the system. -
Page 19: Approaching And Entering The Rack
APPROACHING AND ENTERING THE RACK The forklift truck should approach the rack squarely and not at an angle. No attempt should be made to deposit/retrieve pallets or to enter a rack when the truck is NOT correctly aligned. It is not acceptable to attempt to re-align a truck after entry into the rack. UNACCEPTABLE PALLET HANDLING It is not acceptable practice to: •... -
Page 20: Loading The System
LOADING THE SYSTEM Step 1 Check that the pallet is the correct style and size for the installation. Step 2 Check the underside of the pallet for loose, split or damaged boards. Damaged pallets should not be entered into the racking. Step 3 The fork lift truck driver inserts the forks into the pallet, and picks the pallet up ensuring that it is square and that the forks are evenly spaced within the... -
Page 21: Unloading The System
UNLOADING THE SYSTEM Step 1 The forklift truck approaches the rack squarely and aligns itself centrally with the desired lane. Step 2 Slow down and stop the truck at the entrance to the lane. Reduce any tilt on the mast and raise the forks to the required storage level ensuring the truck is still central between the pallet rails. -
Page 22: Safety - Never Work Under Pallets
Deepstor User Instructions SAFETY – NEVER WORK UNDER PALLETS It is unsafe for operators and fork lift trucks to enter a rack beneath pallets that are stored on levels above. This is dangerous and MUST be avoided. This situation could occur when the rack has either been loaded or unloaded out of sequence. The correct sequences are detailed on the previous two pages. -
Page 23: Cleaning The Installation
Deepstor User Instructions CLEANING THE INSTALLATION Should the rack need cleaning, either as part of a routine, or as a result of a spillage the following guidelines should be observed. The clean should comprise of a wipe down with a damp cloth, using (if required) a mild detergent. NEVER use a hose to spray the racking. -
Page 24: Routine Inspection / Maintenance
ROUTINE INSPECTION / MAINTENANCE It is recommended that the end user refer to Section 9 - “Operation and Maintenance of Adjustable Pallet Racking” of AS4084:1993 (Steel Storage Racking) for racking inspection and maintenance procedure. As a supplement to the code recommendation, the following information has been compiled based on AS4084:1993 and the FEM recommendation. -
Page 25: Inspection Intervals
Deepstor User Instructions INSPECTION INTERVALS Daily Inspections This applies to operator care of the system. Ensure the correct application and use of equipment. Ensure that the safe working loads are adhered to. Damaged pallets must not be entered into the system and should be removed as they occur. Any safety issues or damage to the structure should be reported to the Safety Officer who will carry out the risk assessment and identify the risk as necessary. -
Page 26: Damage To The Storage Equipment
Deepstor User Instructions The following pages detail the damage assessment procedure and the risk identification using colour-coding method as per FEM. DAMAGE TO THE STORAGE EQUIPMENT INTRODUCTION Almost all damage to pallet racking is a result from a collision by a fork lift truck, or from the pallet the truck is transporting. -
Page 27: Component Recognition
COMPONENT RECOGNITION The Deepstor racking installation comprises of the following main elements: • Load Arm and Automatic Safety Lock • Pallet Rail and Fixings • Pallet Rail Splice and Fixing • Top / Back bracing and Top Channel • Upright Frames, comprising uprights, bracing and Base plates. Each should be inspected to the following recommendations. -
Page 28: Damage Inspection - Load Arm And Safety Lock
Any damage on the arm or tearing and cracking of any hooks, replace the arm immediately. If the slots are also damaged, the entire level of arms and rail may have to be relocated. Consult a Dexion representative for rack capacity prior to any level adjustments. ISSUE 1... -
Page 29: Damage Inspection - Pallet Rail
DAMAGE INSPECTION – PALLET RAIL Fixing Missing: Replace immediately Damage to fixing; Damage to M6 Nut and Bolt by shearing, replace the fixing immediately. When damage on fixing occurs, often, pallet rail is also damaged. If the damage is limited to hole enlargement, replacement with new fixing using a large washer may be adequate. -
Page 30: Damage Inspection - Rail Splice & Fixing
DAMAGE INSPECTION – RAIL SPLICE & FIXING Splice & Fixing Missing Replace immediately Damage to Fixing & Rail: Damage to M6 or M10 bolts and nuts by shearing, replace the fixing immediately. When damage on fixing occurs, often, the fixing holes on both pallet rail and splice are also damaged. -
Page 31: Damage Inspection - Top / Back Bracing & Fixing
DAMAGE INSPECTION – TOP / BACK BRACING & FIXING Fixing Missing: Replace immediately Damage to fixing; Damage to M10 x 25 Gr 8.8 Nut and Bolt by shearing, replace the fixing immediately. When damage of fixing occurs, most likely either the upright slots or hole on the brace or both are badly damaged. -
Page 32: Damage Inspection - Frames
DAMAGE INSPECTION – FRAMES FEM quantifies damage to frame uprights and bracing as either Green, Orange or Red risk. These rules only apply to damage that produces an overall bend in a component. They do not apply to highly localised damage such as dents, buckles , tears and splits. Bends are judged against a 1000mm straight edge, localised bends over a shorter length should be judged pro-rata, i.e. -
Page 33: Damage Inspection - Rack Out-Of-Plumb
Deepstor User Instructions DAMAGE INSPECTION – RACK OUT-OF-PLUMB Due to an impact (e.g. fork truck collision), a rack may be out-of-plumb by a certain amount. A recommended maximum amount of out-of-plumb for a rack in an unloaded condition, both along the aisle and across the aisle directions, is Height/350. -
Page 34: Risk Assessment
Deepstor User Instructions RISK ASSESSMENT GREEN RISK Damage requiring surveillance. For damage to frames in which the limits illustrated are not exceeded. This would indicate racks where some damage was present but was considered non-critical. Such damaged components should be recorded as suitable for further service until the next management inspection, but clearly identified for further re-examination at future inspections. -
Page 35: Damage Action Procedure Flowchart
DAMAGE ACTION PROCEDURE FLOWCHART Red Risk Immediately off-load all affected bays of racking and repair damage before re- use. The necessary repairs or replacement of all damaged parts are correctly carried out. Return to service ISSUE 1 AUGUST 2003 Rack is damaged Safety officer to assess and classify the damage... -
Page 36: Typical Causes Of Damage
TYPICAL CAUSES OF DAMAGE The following are some typical contributing factors to why damage can occur. Handling equipment: Poor or ill maintained equipment, or a change in the type and size of handling equipment. The pallet Change in the type or size of pallet used, damaged pallets, load overhang affecting operational clearances. - Page 37 Deepstor User Instructions BLANK User Instruction ISSUE 1 Page 31 AUGUST 2003...
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