As per the latest Australian Standards (AS: 4084:2023), at the end of every row of pallet racking there should be a load sign which displays vital information on the load capabilities as per the manufacturer’s recommendation.
Some companies have them but several don’t. For those that do have them, a significant number is unfortunately out of date or not an accurate reflection of the configuration as it currently stands. One of the most common issues is the height of the 1st and 2nd beam levels. In recent times and as per the Australian Standards, the load sign should state what heights the beams are positioned from the ground. The problem is product profiles change so warehouse staff (with the best of intentions) diligently change the beam levels to suit that new product profile.
Unfortunately for them, the beam levels are very important when it comes to calculating the bay load. For clarity, the bay load is the combined weight an individual bay can carry across the total number of beam levels, not including the ground position. Lowering 1st and 2nd beam levels generally increase the bay load while lifting the beam heights will lower the bay load. If you remove one of those beam levels altogether, you are weakening the structure. Apart from holding products off the ground, the beams help tie the structure together and stop the frames from moving or sliding apart.
As discussed in previous blogs, we constantly walk into warehouses and when discussing load signs and the importance of NOT changing beam levels without the manufacture’s permission, we get blank expressions or excuses that “we had to so we could fit the new product profile”. The problem with pallet racking is that is too easy to change the configurations and most users don’t understand or think about what those changes will do and how it impacts the loading capability.
Responsible pallet racking manufacturers will go to great lengths to test their racking, understand what the structure is capable of being loaded too in various configurations or environments. Racking placed outside will have different loadings than the very same racking that is set up inside a warehouse. Why, because the elements such as wind will have a direct impact with the force it places on the structure and the product.
There is much greater awareness around loading trucks, what they can carry and what their payload is. Most drivers understand that there is a limit they can’t exceed and they will ensure to the best of their ability that they follow the manufacturers’ recommendation. A big reason for this is that they know the Police monitor them on the roads and that if they have an accident and the truck is overloaded that there is no insurance and they are liable.
Unfortunately, with pallet racking, people don’t have the same awareness and don’t realise or understand the importance of adhering to the load calculations. Just as a transport company is accountable under “Chain of Responsibility” when it comes to the loading of trucks, businesses have the same responsibility in ensuring racking isn’t overloaded and that it has the correct and current certification, by way of the load sign.
So, what does a load sign look like and what does it all mean?
The most important information is about the weights and beam heights. In the example below you can ascertain the following:
- Maximum weight per pallet is 1000kgs
- Each pair/level of beams is rated to take a maximum of 2000kgs UDL which means Uniformly Distributed Load i.e. weight is evenly spread across the beams.
- The maximum load this bay can take is 10,000kgs when fully loaded. Assuming there are 5 beam levels, that equates to, 2000kgs per beam level. The bay load only considers the beam levels and doesn’t include ground positions.
- The first and second beam heights are set at 1500mm and 3000mm from the ground. These 2 measurements are used to calculate the frame and beam capacity. If those heights get changed, the bay load will also change.
Unfortunately, some racking providers under spec the racking compared to what the client believes they are receiving. Any easy way to know is making sure that the bay load (10,000kgs), divided by the number of beam levels (5) = the maximum weight per pair of beams (2000kgs).
Using the example above, if the bay load is under 10,000kgs, such as 9000kgs, but the UDL is 2000kgs, then you can only have 4 beam levels of 2000kgs and one level of 1000kgs. Even though each beam level may be rated for the full 2000kgs, the racking provider is assuming that each pallet won’t weigh 1000kgs, therefore the client will never need it to be rated at 10,000kgs.
It is important that if you oversee a warehouse operation, your staff understand the load signs. It is one of the most critical requirements in a warehouse. Overloaded racking is dangerous as it is always a matter of “when” the racking will be hit by a forklift, not “if”. Forklifts hitting racking is never ideal, but if overloaded, there is a far greater chance of collapse.
Other important information that should be on the load sign is:
- Client Name and Address.
- The Brand of racking.
- Who provided the racking.
- Who Installed the racking.
- The standard that the racking complies too i.e. AS4084:2023
Absolute Storage Systems offers pallet racking audits and part of that process is ensuring the load signs are an accurate reflection of the racking as it stands. If you have re-configurated, in most cases and with most brands, we can re-calculate the loadings to ensure you are compliant.
If you have any concerns about accuracy of the sign or staff knowledge, we offer comprehensive pallet racking audits to ensure your load signs accurately reflect your racking’s current setup. Reach out today to schedule an audit and ensure your team is working within safe and compliant limits.
