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Racking Safety Audit Report -CSCL

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Racking Safety Inspection report identifying various unsafe racking conditons

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Racking Safety Audit Report -CSCL

  1. 1. Racking Safety Audit Report Prepared by Julian Kalac, P.Eng. 6/19/2013
  2. 2. Page 2 of 12 CSLC Racking Safety Audit Report 19 June 2013 To: Grant Donnelly, Chris Hawrelak, Bob Bloomer C.C.: Winston Shim, George Asamoah From: Julian Kalac, P.Eng License #90505462 Date: June 19, 2013 Re: Safety Audit Report Overview: I am a Mechanical Engineer and a Professional Engineer (P.Eng.) with over 16 years working in the manufacturing industry with industrial machines/equipment. My experience and training have made me very familiar with OSHA regulations and standards. Objective The objective of this report is to provide an initial assessment of the Pallet Racking Safety conditions and recommend improvement suggestions that ensure full compliance to OHSA standards and regulations. Referenced Standards  CSA A344.1-05 User Guide for Steel Storage Racks  CSA A344.2-05 Standard for the Design and Construction of Steel Storage Racks  ANSI/ALI ALOIM-2000---Safety Requirements for Operation, Inspection/Maintenance Regulation 851-Industrial Establishments Regulation 851 was developed to address the issues specific to all industrial establishments such as factories, offices, arenas, or shops operating within Ontario. It is for this reason that Regulation 851 covers a broad range of requirements on topics such as industrial hygiene, machine guarding, fire prevention, confined spaces, equipment maintenance, material handling, and protective equipment.
  3. 3. Page 3 of 12 CSLC Racking Safety Audit Report 19 June 2013 Certain Sections of Regulation 851 require the preparation of a written report to provide a permanent record regarding the occurrence of health & safety issues. In particular, Section 7 requires preparation of a written report detailing the measures that must be taken for compliance with the relevant provisions listed in the Table There are 5 steps in completing a Pre-Start Health & Safety Review (PSHR) 1. Safety Audit / Risk Assessment 2. PSR (Pre –Start Safety Review) 3. Design And Installation 4. PSR Sign-Off … 5. Training and Documentation In House Racking The pallet racks used in the warehouse are used and have been modified from it’s original design. No PSHR was ever conducted. The main concern is the lack of documented load rating capacity for the racks as well as several safety violations and hazards which are shown in the pictures taken. I was told by the only material handler who uses the rack that the load rating is 9000 Lbs/beam, which is highly unlikely given the 1/8” thickness of the cross section and ¾” Beam Depth. No supporting documentation was provided. Therefore if no documented load ratings are available, a PSHR must be conducted. (see MOL flow chart on Racking PSHR) ¾” 1/8” ”
  4. 4. Page 4 of 12 CSLC Racking Safety Audit Report 19 June 2013 PHSR Regulation 851, section 7 Applicable provisions of Regulation 851 Circumstances 1. Subsections 22 (1), (2) and (4) Flammable liquids are located or dispensed in a building, room or area. 2. Sections 24, 25, 26, 28, 31 and 32 If any of the following are used as protective elements in connection with an apparatus: 1. Safeguarding devices that signal the apparatus to stop, including but not limited to safety light curtains and screens, area scanning safeguarding systems, radio frequency systems and capacitance safeguarding systems, safety mat systems, two-hand control systems, two-hand tripping systems and single or multiple beam systems. 2. The barrier guards use interlocking mechanical or electrical safeguarding devices. 3. Clause 45 (b) Material, articles or things are placed or stored on a structure that is a rack or stacking structure. 4. Section 63 A process involves a risk of ignition or explosion that creates a condition of imminent hazard to a person's health or safety. 5. Section 65 The use of a dust collector involves a risk of ignition or explosion that creates a condition of imminent hazard to a person's health or safety. 6. Sections 87.3, 87.4, 87.5 and 88, subsections 90 (1), (2) and (3), and sections 91, 92, 94, 95, A factory produces aluminum or steel or is a foundry that melts material or handles molten material. 7. Sections 51 and 53 The construction, addition, installation or modification that relates to a lifting device, traveling crane or automobile hoist. 8. Sections 127 and 128 This process uses or produces a substance that may result in the exposure of a worker in excess of any occupational exposure limits as set out in Regulation 833, 835, 836, 837, 838, 839, 840, 841, 842, 843, 844, 845 or 846 of the Revised Regulations of Ontario, 1990.
  5. 5. Page 5 of 12 CSLC Racking Safety Audit Report 19 June 2013 Issue #1 –Beam Connectors damaged due to overloaded (double stacked)pallets Large amount of deflection indicates overloading of the racking. Where two beams connect at an upright, the beam connectors should be parallel. If racking is or has been overloaded, the beam connectors may be deformed There will also be evidence of ‘permanent set’ in unloaded beams. Above pictures shows 6 double stacked skids ~6000Lbs sitting on racking beam which can only hold Max 1500Lbs, causing damage and deflection 6 DOUBLE STACKED SKIDS = 6000Lbs on damaged rack beam which can hold Max 1500Lbs
  6. 6. Page 6 of 12 CSLC Racking Safety Audit Report 19 June 2013 ISSUE # 2 NO SIDE GUIDE RAILS CREATING HIGH RISK OF TIPPING/FALLING DOWN. CRITICAL INJURY!!
  7. 7. Page 7 of 12 CSLC Racking Safety Audit Report 19 June 2013 Locking Pins/keys are inserted into the racking to prevent the unit load from being dislodged unless mesh decks or other form of support structure has been designed and fitted. Missing Locking Pins ISSUE # 3 OVERHANGING SKID CRUSHING INJURY NO SAFETY PINS No Cross Bars
  8. 8. Page 8 of 12 CSLC Racking Safety Audit Report 19 June 2013 SKID ALMOST OFF THE RACK CRITICAL INJURY SHIFTED LOAD –CRUSHING INJURY
  9. 9. Page 9 of 12 CSLC Racking Safety Audit Report 19 June 2013 MOL GUIDELINE FOR PSHR—RACKING
  10. 10. Page 10 of 12 CSLC Racking Safety Audit Report 19 June 2013 Racking Load Capacity
  11. 11. Page 11 of 12 CSLC Racking Safety Audit Report 19 June 2013 Racking design Information needed for Load Calculations The Canadian Standards Association has two standards that provide the information you need.  CSA A344.1-05 User Guide for Steel Storage Racks  CSA A344.2-05 Standard for the Design and Construction of Steel Storage Racks 1. What is the Bay Clear Entry? Single bay racking In situations where single rows are installed, and there is pedestrian access along the rear of the racking, rear protection should be installed to prevent loads falling out of the back of the racking. 2. What is the racking beam section? Open beam or a box beam? The box beam is a heavier duty beam than the open beam, so this is crucial to the strength of the entire racking system and the loading it can take. 11 FT 8F T
  12. 12. Page 12 of 12 CSLC Racking Safety Audit Report 19 June 2013 3. How big are the racking frames? It is important to know the dimensions of the racking frames. The measurement required is the Height (H) (mm) x Width (W) (mm) of the frames. 4. What is the vertical beam pitch of your racking system? The height of each storage level, measured from the floor to the top side of each beam. If the number of beam levels varies across the racking system, then the load criteria will also vary.

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