Safety Guide Selective Pallet Racking -...

Systore Au Pty Ltd

[email protected]

1300 793 634

www.systore.com.au

Safety Guide Selective Pallet Racking

SAFETY GUIDE

SELECTIVE PALLET RACKING

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Table of Contents 1. SCOPE ................................................................................................................................................3

2. AUSTRALIAN STANDARDS ...............................................................................................................3

INSTALLATION PLANNING.......................................................................................................................5

Risk Assessment for Pallet Rack ............................................................................................................6

INFORMATION RELEVANT TO USER .....................................................................................................7

PLACEMENT AND RETRIEVAL OF GOODS ............................................................................................8

2.11. MINIMISE FORCES ..................................................................................................................8

2.12. UNACCEPTABLE PALLET HANDLING ...................................................................................8

2.13. APPROACHING AND ENTERING THE RACK ........................................................................9

2.14. OPERATING CLEARANCES ..................................................................................................10

MAINTAINING OPERATING CLEARANCES .......................................................................................11

3. DESIGN & LAYOUT OF PALLET RACKING ....................................................................................11

4. STORAGE SYSTEM MAINTENANCE ..............................................................................................12

5. COMMON TYPES OF PALLET RACKING DAMAGE .......................................................................12

8.1 EXAMPLES OF IMPACT DAMAGE..............................................................................................13

6. REPORTING DAMAGE .....................................................................................................................14

7. IMPACT PROTECTION DEVICES ....................................................................................................14

7.1 EXAMPLES OF PROTECTIVE DEVICES .....................................................................................14

7.2 EXAMPLES OF PROTECTIVE DEVICES CONTINUED ...............................................................15

Damaged Uprights .............................................................................................................................16

Damaged Bracing ..............................................................................................................................17

Damaged Beams ...............................................................................................................................17

Damaged Beam Connectors .............................................................................................................17

Load Signs ...............................................................................................................................................18

8. RACK DAMAGE ASSESSMENTS ....................................................................................................19

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8.1. GREEN RISK:.............................................................................................................................19

8.2. ORANGE RISK: ..........................................................................................................................19

8.3. RED RISK: ..................................................................................................................................19

9 RACK DAMAGE ASSESSMENT .........................................................................................................20

8.4. ASSESSMENT OF DAMAGE TO UPRIGHTS & BRACING MEMBERS ...................................21

8.5. RACKING INSPECTION ............................................................................................................22

8.6. CHANGES TO THE STORAGE SYSTEM .................................................................................22

9. CONCLUSION ...................................................................................................................................23

Daily Check of Installation .....................................................................................................................24

RACK AUDIT ABBREVIATIONS ..............................................................................................................26

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1. SCOPE This guide has been developed to provide users with information specific to safe use of Pallet Racking Storage Systems. The guide provides useful information to assist with determining design, layout and maintenance of pallet racking storage systems.

2. AUSTRALIAN STANDARDS

There are “Australian Standards” that are to be adhered to and covering the design and use of pallet

racking storage systems.

You should only purchase a system from a supplier who complies with the Australian Standards.

All new installations and alterations to existing structures should also comply with the relevant

standards.

SYSTORE Pallet Racking (D-RACK) has been designed and tested to meet or exceed the following

Australian Standards:

2.1. AS4084–2012 Steel Storage Racking 2.2. AS/NZS 4600:2005 Cold Formed Steel Structures 2.3. AS4100-1998 Steel Structures 2.4. AS4100-1999 Steel Structures Commentary 2.5. AS/NZS1170 Series-2002 Structural Design Actions 2.6. AS/NZS1170.0-2002 General Principles 2.7. AS/NZS1170.1-2002 Permanent, Imposed and Other Actions 2.8. AS 1170.4-2007 Structural Design Actions – Earthquake actions in Australia 2.9. AS1657-1992 Platforms, Walkways, Stairways and Ladders

2.10. AS2143-1978 Industrial and Commercial Steel Shelving

Installations prior to 29th February, 2012 are designed to AS4084-1993. Reference is also made to the recommendations of EN 15512 – European Racking Code RMI 2008 – Rack manufacturers Institute of America for the design of our racking systems.

Inspection criteria All racks were inspected in accordance with the following criteria: Ref: AS 4084-2012 Page 100, Section 8.2 "INSPECTIONS -Inspections shall be carried out on a regular basis, and at least once every twelve months to ¬ a) Ensure the correct application and use of equipment; b) ensure that the safe working loads are adhered to;

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c) ensure that the racking installation has not been altered. A copy of the load application and Configuration drawings shall be retained for this purpose; d) examine the extent of damage due to impact in the racking installation;

e) examine the out-of-plumb of the racking; f) examine for any dislocation and deformation of sections and connections for uprights and beams g) Examine connectors for deformation or signs of cracking of the welds; and h) examine base plates and floor anchor Ref: AS 4084-2012 Page 63, Section 6.4.1 "On racking serviced by mechanical equipment, a minimum of two anchors per base plate shall be used. Ref: AS 4084-2012 Page 64, Section 6.6 "UPRIGHT SPLICES -In general upright splices shall be avoided. A splice should not be allowed below the lowest beam level or below 105m. Ref: AS 4084-2012 Page 101, Section 8.3.5 "Connectors -Connectors shall not show visible permanent deformation or signs of cracking of welds". Ref: AS 4084-2012 Page 100, Section 8.3.1 "General -The extent of damage due to impact in the racking installation determined from regular inspections and reports of damage incurred shall be assessed in accordance with Clauses 8.3.2 to 8.3.6. Damage levels shall be specified and appropriate actions shall be taken in accordance with clause 8.5" Ref: AS 4084-2012 Page 102, Section 8.5 8.5.2 Acceptable damage (Green) When the level of damage does not exceed the permissible limits specified in Clauses 8.3.2 to 8.3.4, the racking shall be considered serviceable. 8.5.3 Hazardous damage (Amber risk) When the level of damage exceeds the limits of Clauses 8.3.2 to 8.3.4 by up to a factor of 2, the damage section shall be clearly marked and isolated until remedial work has been carried out before the racking can be reloaded. 8.5.3 Hazardous damage (Amber risk) When the level of damage exceeds the limits of Clauses 8.3.2 to 8.3.4 by up to a factor of 2, the damage section shall be clearly marked and isolated until remedial work has been carried out before the racking can be reloaded.

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INSTALLATION PLANNING In order to determine the design of storage equipment, the following information should be considered. 1. The properties of the storage equipment foundation (floor). 2. The characteristics of goods required to be stored on the equipment. 3. Details of the building in which the storage equipment is to be housed, its environment, or if outside, it’s exposure to wind and the weather. 4. The required layout and configuration of the equipment to allow sufficient design clearances and product flow to be provided for the safe depositing and retrieval of goods. 5. The specification of allowable loads for the storage equipment, load ratings of the pallet racking structure and suitability for the goods being stored. 6. The specification of Mechanical Handling Equipment (MHE) to be used with the storage system. The knowledge of the truck’s lift height, turning radius and practical aisle width requirements. 7. The specification of load carrying accessories, for example pallet, stillage, etc. 8. The installation of storage equipment. 9. All known information about planned future changes to storage requirements. 10. The specified requirements for collision protection and resistance to impact. A safety inspection process to ensure integrity of storage system components is considered vitally important. An inspection process can be completed internally or by an external specialist.

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Risk Assessment for Pallet Rack

Risk management for pallet racking structures The following specific controls should be implemented to manage risk within and around pallet racking structures

• Risk Identification

• Risk Assessment

• Risk Control

• Risk Review

• Risk identification

Risk identification is being aware of a health and safety hazard in the workplace. What we look for to identify risks in pallet racking structures? Damage from impact Damage from impact is the most common cause of rack failure. We look for any visible signs of impact on the rack structure. Any visible signs of impact are assessed. The most common area of impact damage occurs around the base of the upright and is caused by collision from forklift trucks, outrigger supports (on Reach Trucks) or the unit loads themselves, but can occur at any point along the height of the upright, and on both the front and rear upright posts. We look for indentations or localized deformation at the face or sides of the material, tearing at the edges of the material or around the holes, crushing of the section or excessive deformation of the fianges. We also look for twist at the base of the upright and check that the base plate is sitting squarely on the floor, perpendicular to the aisle. The bracing at the lower levels is also a common area of damage caused by insufficient clearances, uneven or angled entry of the unit load, overly adjusted side shifted loads, or overhanging loads. We look for excessive deformation or bowing of the section and any sign of stress around the connections.

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INFORMATION RELEVANT TO USER In order to promote the safe use of storage equipment, the user must understand the following points: 1. The storage equipment must be constructed in accordance with the design specifications. Please consult with your supplier for any deviations to the design specifications. 2. The building floor (foundation) must be capable of withstanding the upright loads and of receiving the base plate fixings. The floor must have a suitable degree of surface level tolerance and flatness. 3. The load carrying capacity of storage equipment depends on the components chosen, the configuration of those components, the floor properties and the way in which the installation is used. 4. In the event product characteristics have changed and the user intends to modify the design of the existing racking, it is recommended the user consult with their supplier prior to proceeding with such changes. Alterations will have a significant bearing on load ratings and integrity. 5. In order to instruct the fork lift operator, a printed load sign must be supplied giving sufficient and unambiguous loading information on the equipment. It is the user’s responsibility to ensure the maximum load conditions are not exceeded. 6. The method of equipment operation must be in accordance with the design information supplied to the user by the supplier of equipment. 7. The lift truck chosen for operating with storage equipment is appropriate for safe unloading and loading of goods. The turning circle of the lift truck combined with the gross dimensions of the unit loads must be suitable for the rack aisle width provided. 8. Fork lift operator training must be provided to all operators to ensure safe operations in and around the storage system. This is critically important with placement and retrieval of goods and movement in and around the storage system.

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PLACEMENT AND RETRIEVAL OF GOODS

2.11. MINIMISE FORCES

In order to minimize forces placed upon storage systems the following points should be considered: 1. Operators should check that the weight of the goods is within the design limits of the storage system prior to placing goods. 2. Operators must ensure the pallet is correctly aligned with the pallet racking. 3. Operators should ensure the fork lift mast is well clear of storage system prior to elevating or lowering goods. 4. Operators must appropriately position the pallet to ensure it is evenly positioned across the support beams. Front and rear overhang should be equal. 5. Operators should allow adequate clearances between pallet positions and frames when placing pallets into the pallet racking. 6. Care should be taken when lowering pallets onto support beams. Abrupt lowering applies significant force and may result in damage to support beams. 7. Operators must not drag or push the pallet whilst in contact with the support beam. The pallet should be slightly elevated before repositioning.

2.12. UNACCEPTABLE PALLET HANDLING

It is not acceptable practice to: Nudge one pallet with another, in an attempt to move or re-align loads. Drag or slide pallets on or against the support beams or structure. These are dangerous practices that impart additional loads to the rack structure, and could lead to damage and a reduction in safety factors.

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2.13. APPROACHING AND ENTERING THE RACK

The fork lift/truck Operator should approach the rack squarely and not at an angle. No attempt should be made to deposit/retrieve pallets when the truck is NOT correctly aligned.

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2.14. OPERATING 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. OPERATING CLEARANCES The rack dimensions will have been designed to provide operating clearances between the pallet and the adjacent rack structure or adjoining pallet/s. The amount of recommended clearance varies slightly according to the rack height and the type of handling equipment in use. These recommendations have been specified in AS4084-2012.

a = 75mm b = 100mm c = 75mm up to 6 meters, then 100mm above 6 meters x = the front to back pallet dimension y = the pallet racking frame depth z = 100mm

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MAINTAINING OPERATING CLEARANCES It is important to maintain operating clearances to ensure safe working practices, a loss of clearance leads to an increased risk of damage to the rack structure, and a reduction in fork truck driver efficiency. The following can cause reductions in clearances:

• Storing an oversized pallet.

• Storing a pallet with load overhang when the design doesn’t allow for it.

• Misplacing the first pallet, thereby not allowing sufficient space for subsequent loads.

• Misplacing floor level pallets so that they protrude into the operating aisle.

• Storing a pallet that has been picked up out of alignment.

3. DESIGN & LAYOUT OF PALLET RACKING

The design and layout of pallet racking systems must be considered with the relevant codes and operational requirements of the storage system, and the Mechanical Handling Equipment (MHE) to be used. Protective devices should be used in accordance with the requirements of AS4084-2012 and other applicable workplace regulations. MHE exclusion zones should be set up to reduce the level of traffic within close proximately to pallet racking systems, or within congested work areas. Pedestrian crossings should be set up where pedestrians cross MHE traffic lanes. This forms part of the site specific traffic management plans.

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4. STORAGE SYSTEM MAINTENANCE It is important the user determines an effective “Inspection Process” to ensure the integrity of storage system components are not compromised. Damage may appear superficial at first glance, but must be checked to ensure the integrity of components are not compromised. Movements of materials within the damaged section of racking could result in component failure with catastrophic results. Rack damage should be reported immediately following the incident in which the damage had occurred. Unfortunately, employees are not always forthcoming in reporting incidents, hence the need to carry out regular inspections. The following details will assist with determining such an inspection process.

5. COMMON TYPES OF PALLET RACKING DAMAGE

The following list represents common types of damage to pallet racking systems

• Impact to Uprights, generally caused by MHE

• Damaged Uprights, as the result of rear Upright impact caused by pallet or fork tynes

• Sheared anchor bolts, generally the result of Upright impact caused by MHE or fork tynes

• Damaged Horizontal or Diagonal Brace, generally the result of impact caused by MHE

• Damage to base and leveling plates, generally caused by Upright impact caused by MHE

• Impact to Beams, generally caused from fork tynes not correctly aligned in the pallet, or fork lift/mast impact

• Beam Deflection, generally caused by loads exceeding Beam capacity or weight of goods not uniformly distributed across Beams

• Beam dislodgement, generally caused by missing or damaged Beam locks The most common cause of all Pallet Racking Damage is MHE impact through operator error.

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8.1 EXAMPLES OF IMPACT DAMAGE

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6. REPORTING DAMAGE In order to ensure the integrity of the storage system, it is critically important that a reporting system is developed and used. The reporting of damage to components will enable appropriate action to replace or repair damaged components. The reporting process needs to be simple but effective. Using the concept of Red, Orange and Green tagging is recommended. It is important employees are appropriately trained regarding the reporting system. Employees need to understand the importance of the reporting system and the ramifications should they chose to ignore the process.

7. IMPACT PROTECTION DEVICES

Impact resistance as required by AS4084-2012 must be included in the design of the system. The type of protective devices are determined by the MHE used together with the design layout.

7.1 EXAMPLES OF PROTECTIVE DEVICES

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7.2 EXAMPLES OF PROTECTIVE DEVICES CONTINUED

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Damaged Uprights

Unless specifically designed to withstand horizontal forces, most pallet racking uprights are not capable of absorbing

horizontal forces caused by impact from forklift trucks or their loads. Any signs of visible damage are inspected and

measured to ensure it does not exceed those stated in AS4084, Section 9.3.

A straight edge 1000mm long is placed in contact with a flat surface on the face of the damaged member so that the damaged area lies central, as near as possible to the length of the straight edge.

For an upright bent in the direction of the rack beam spans, the maximum gap between the upright and straight edge should not exceed 5mm. For an upright bent in the plane of the frame bracing, the maximum gap between the upright and straight edges should not exceed 3mm.

Fig. 6.1 -AS4084 Method of Measurement for Visible Upright Damage

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Damaged Bracing

Bracing can either be damaged by direct impact from unit loads, or indirectly by forces transferred to them as a result of impact on the uprights. For bracing damage, the member deviation from a 1-meter straight edge in either plane must not exceed l0 mm.

Damaged Beams

Beams defect vertically when under load and this is quite acceptable if the deflection is within the limits of the standards -AS4084 = L/180. If beams are deflecting beyond the acceptable limits it could be a sign they are overloaded. The Maximum permanent horizontal beam deflection in an unloaded condition = Span/SOD Comparison measurements must be made between straight, level edges, such as a second beam level set below the suspect beam. To take a measurement the comparison beam and the suspect beam must be unloaded. Three vertical measurements are taken from the centre and two outer edges of the suspect beam and the difference is the permanent defection. The maximum permanent vertical beam deflection in an unloaded condition = Span/800

Damaged Beam Connectors

AS4084 states ".... connectors shall not show visible permanent deformation or signs of cracking of welds....". When inspecting the beam connectors look for signs of stress or overload. This could appear as cracks in the surface finish, bending or bowing of connector edges or signs of cracking or excessive bending of individual connector lugs or 'prongs'

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Load Signs

AS4084 -1.6.1 General to comply with this Standard, a racking shall comply with all of the following: (a) The racking installations shall have, in one or more conspicuous locations, a permanent corrosion-resistant plaque not less than 125 mm long and 250 mm high with minimum 25 mm high lettering and mechanically secured to the racking structure at 2.0 m above the floor level, which shall contain the following: (i) Racking manufacturer's name and trademark. (ii) Safe working unit load. (iii) Safe working unit load for each shelf beam level

(iv) Safe working total unit load for each bay.

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8. RACK DAMAGE ASSESSMENTS The Risk Assessment process is based on a simple concept using Red, Orange and Green tags or stickers as a means of reflecting the severity of the damage/risk.

8.1. 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 inspection, but clearly identified for further re-examination at future inspections.

8.2. ORANGE RISK: Hazardous damage requiring action as soon as possible For damage to frames in which the limits illustrated are exceeded by up to a factor of two. This would identify an area where the damage was sufficiently severe to warrant remedial work but not so severe as to warrant the immediate off-loading of the rack. Once the rack is unloaded however, it should not be re-loaded until repairs have been carried out. In the event that the storage position remains full for several days after the initial identification of the problem, the rack should be off-loaded for repair without further delay. The USER Company must have a method of isolating such racks to ensure that they do not come back into use until the necessary repairs have been carried out and the equipment certified as safe. For example, use could be made of dated adhesive labels, which indicate racks that are not to be re-loaded until rectified. In practice any racking with ORANGE RISK category damage should be re-designated RED RISK damage if remedial work has not been carried out within four weeks of the original designation.

8.3. RED RISK: Very serious damage requiring immediate action For damage to frames in which the limits illustrated exceed a factor greater than two. These are situations where a critical level of damage is identified which warrants an area of racking being immediately off-loaded and isolated from future use until repair work is carried out. Such repair work would involve replacement of the damaged item. USER Companies must have a method of isolating areas to ensure that they do not come back into use prior to the repair work being carried out. For example, a particular bay could be off-loaded in the presence of the inspector and roped off to prevent further use.

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9 RACK DAMAGE ASSESSMENT

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8.4. ASSESSMENT OF DAMAGE TO UPRIGHTS & BRACING MEMBERS

A steel straight edge 1.0-meter-long is placed in contact with a flat surface on the concave side of the damaged member. The damaged area lies central to the steel straight edge. For an Upright bent in the direction of the support beams, the maximum gap between the point of damage to the straight edge should not exceed 5.0 mm. For an Upright bent in the direction of the bracing, the maximum gap between the point of damage to the straight edge should not exceed 3.0 mm. For an Upright which has been damaged in both lateral directions, the front to back and left to right damage shall be measured independently and appropriate limits observed. For damage to bracing members, the gap between the damaged point and the straight edge should not exceed 10.0 mm.

For assessment of beam damage, the residual vertical deformation when unloaded shall not exceed 20% of the allowed vertical deflection. Check beams for twisting, impact damage, cracking of welds and hook deformation. Also check safety locks are fitted correctly

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8.5. RACKING INSPECTION

It is essential that the storage systems are inspected in-house at least once per month. The inspection process should be adopted by internal staff as a means of enhancing general awareness. Using an Inspection Report, each bay should be checked for damage, corrosion, missing beam locks etc. Items identified during the inspection process should be appropriately corrected. Details of the inspection should include

• The location in which the damage had been identified

• The type of damage or non-conformance identified

• The risk rating as far as RED, ORANGE or GREEN When the report is complete, a copy should be issued to the Site Manager or designated Rack Maintenance Officer. A copy of the report should also be filed as evidence of compliance External consultants should be invited to carry out an annual inspection. This ensures emergent changes or issues not identified in the internal process are appropriately actioned.

8.6. CHANGES TO THE STORAGE SYSTEM

A change in a rack configuration will cause a change in the load carrying capacity of the rack . In both braced and unbraced racking, if the height to the first beam level, or the space between beams is increased the safe load capacity of the frames may be reduced. The following points should be observed:

• Before any alterations are made the supplier must be consulted to check the structural adequacy of the proposed changes.

• Additions or changes to the storage equipment by welding or bolting is not permitted.

• Safe load notices must be replaced as necessary after changes to the rack configuration and load weight.

• During any alteration, for safety, the rack must be completely unloaded.

• Changes should only be made in a professional manner and in accordance with the supplier’s instructions.

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9. CONCLUSION The examples in this guide are for training purposes only There are many factors which can affect stability and consequently the safe use of racking systems. The following points are deemed critical for the safe use of pallet racking systems

• Installations and repairs are carried out by approved and competent contractors.

• All installations comply with relevant Standards

• Any materials or equipment used must also comply with relevant Standards.

• An ongoing documented Inspection and Reporting System should be implemented. • There should be an ongoing fork lift operator training program implemented to ensure

operators are suitably qualified. • Major Inspections of pallet racking systems should be carried out at least every 12

months, (six months in high access areas). This Major Inspection will generally require the use of a scissor lift to inspect all components at higher levels. Many businesses will use their racking supplier for this Major Inspection

• In addition to the Major Inspection, a regular walk around inspection should be carried out by the user. This could be on a monthly basis for low access areas, or weekly / daily for high access areas.

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Daily Check of Installation

Date Comments Name of Person

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Date

Area / Location

MAINTENANCE LOG Damage Description

Level of Damage

Green, Orange & Red Risk

Authorised

By

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RACK AUDIT ABBREVIATIONS

FRAME:

RF Replace Frame

RA Re-Align & Re-Level Rack

FL Flip Frame

FOOTPLATE:

FS Straighten Footplate

FF Tighten Footplate Fixing

FR Replace Footplate

UPRIGHT:

RU Replace Upright

IN Invert Upright

SU Straighten Upright

URS Splice Damaged Upright

UPRIGHT GUARD:

RG Replace Upright Guard

RE Repair Upright Guard

IU Install Stand-Off Upright Guard

CROSS BRACING:

CH Replace Horizontal Bracing

CD Replace Diagonal Bracing

SO Replace Stand-Off Brace

BEAMS:

BN Fit New Beam

BF Re-Fit Beam – All Hooks Engaged

BL Beam Safety Lock Missing

SPLICE:

SA Splice Upright – Priority

SB Splice Upright – Secondary

SC Splice Upright – Monitor

SAFETY LOAD SIGNS:

SL Supply New Safety Load Sign

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