DEEPSTOR DRIVE-IN PALLET RACKING USER INSTRUCTIONS
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DEEPSTOR 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.
Deepstor User Instructions MANUAL AMENDMENT REGISTER DEEPSTOR USER INSTRUCTIONS Issue / Amendment Date Issued Description Issue 1 Aug 03 Original Issue.
Deepstor User Instructions TABLE OF CONTENTS INTRODUCTION ...................................................................................................................1 OPERATOR TRAINING .............................................................................................................................. 1 INSTALLATION DATA SHEET ................................................................................................................... 2 GLOSSARY OF DEXION TERMINOLOGY.................
Deepstor User Instructions DAMAGE INSPECTION – FRAMES ......................................................................................................... 26 DAMAGE INSPECTION – RACK OUT-OF-PLUMB .................................................................................. 27 RISK ASSESSMENT...........................................................................................................28 GREEN RISK ........................................................................................
Deepstor User Instructions INTRODUCTION Deepstor is the product name for the Dexion drive-in pallet racking system. The system comprises parallel rows of frames and individual uprights, interconnected in the left to right direction with top ties, and in the front to back direction with pallet support rails. Top bracing, back bracing, and frame bracing provide the structure with overall stability.
Deepstor User Instructions 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: x mm. Pallet handled on the: mm face. Load size (left to right) mm. Load size (front to back) mm. Any load overhang must be even on both sides. Pallet + Load Height: mm. Pallet Load: Kg maximum.
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. It is important that these are not exceeded and that the rack is not altered without consultation.
Deepstor User Instructions 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. Level: An individual storage level within a lane. Could be either at floor level or at a raised level where the pallets are stored on pallet rails.
Deepstor User Instructions 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.
Deepstor User Instructions PALLET WEIGHT The pallet weight is the combination of the ‘self weight’ of the timber pallet + ‘load’. 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.
Deepstor User Instructions PALLET ILLUSTRATION Direction of travel 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 2way entry pallet.
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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. LIFT HEIGHT The truck must be capable of lifting the pallet clear of the top storage level by at least 100mm.
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. LOAD BEARING ON THE PALLET RAIL When the pallet has been lowered onto the pallet rails there must be a minimum of 20mm bearing between pallet and rail.
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. Refer to Operational Clearances for illustration.
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. Misalignment also increases the effective size of the pallet leading to a reduction in operating clearances.
Deepstor User Instructions 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: • Nudge one pallet with another, in an attempt to move or re-align loads.
Deepstor User Instructions 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. 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 pallet.
Deepstor User Instructions UNLOADING THE SYSTEM Step 1 Step 2 Step 3 Step 4 Step 5 The forklift truck approaches the rack squarely and aligns itself centrally with the desired lane. 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. Drive slowly into the lane up to the desired pallet location.
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.
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. NEVER use abrasive or caustic cleaning agents.
Deepstor User Instructions 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.
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.
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. Any damage will reduce the ultimate load carrying capacity of the rack to some degree thereby eroding the design safety factors.
Deepstor User Instructions 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.
Deepstor User Instructions DAMAGE INSPECTION - LOAD ARM AND SAFETY LOCK ARM WITH SAFETY LOCK IN PLACE Safety Lock Use Missing: Automatic Safety Lock is located on all Deepstor arms except the front and rear uprights in a lane. Front and rear uprights are to be bolted in position using 1 - M8x16 Nut and Bolt with 1 - M10 large washer.
Deepstor User Instructions 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. If tearing of the hole occurs, do not reuse the hole as repositioning of the fixing hole will be required.
Deepstor User Instructions 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. Since the splice is a crucial element in the rail, it is recommended that the splice be replaced immediately. Note that the rail may also need to be replaced.
Deepstor User Instructions 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. A replacement of damaged brace and upright is recommended. Brace Looseness; Due to slight impacts or movement of the rack over a period, the brace can become loose.
Deepstor User Instructions 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. over a half metre length half the limit applies.
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.
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. ORANGE RISK Hazardous damage requiring action as soon as possible.
Deepstor User Instructions DAMAGE ACTION PROCEDURE FLOWCHART Rack is damaged Safety officer to assess and classify the damage Red Risk Immediately off-load all affected bays of racking and repair damage before reuse. Orange Risk Green Risk 1. Identify damage for repair. Record the extent of the damage and reassess at the next inspection, but, within 12 months 2. Order materials. 3.
Deepstor User Instructions 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.
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