MECA Operations Manual - Shuttle Rack System

7/25/2019 MECA Operations Manual - Shuttle Rack System

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PAGE 2OPERATORS GUIDE SHUTTLE RACK SYSTEM


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SHUTTLE RACK SYSTEM INSPECTIONS

SHUTTLE RACK SYSTEM INSPECTIONS

SECTION 17:

SECTION 16:

SECTION 15:

SECTION 14:

SECTION 13:

SECTION 12:

SECTION 11:

SECTION 10:

SECTION 9:

SECTION 8:

SECTION 7:

SECTION 6:

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9SECTION 5:

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SECTION 1: INTRODUCTION 4

SECTION 2: 5

SECTION 3: AUSTRALIAN STANDARDS

SECTION 4: PRODUCT OVERVIEW

GENERAL USE & INSTALL

DEFINITIONS OF RACKING

RACKING DESIGN

13

UNIT LOAD HANDLING SEQUENCE

MAINTENANCE

CONFIGURATION

CHANGES

LIFTING TRUCKS

SAFE WORKING LOADS

HANDLING LOADS

PRECAUTIONS & DAMAGE RED FLAGS

REPLACE OR REPAIR?

CONDITIONS OF WARRANTY

OPERATORS GUIDE SHUTTLE RACK SYSTEM


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acking conforms to Australian Standards AS4084-2012.Shuttle Rack System

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SECTION 1

SAFETY FIRSTMost accidents are caused by operator carelessness or misjudgement. You must at all timeswatch for hazardous situations and correct them. All personnel operating within thewarehouse must be trained in safe working practises.

The information in this guide is intended to improve operators understanding about effective andsafe use when using a forklift and aMECARead this guide thoroughly before commencing use of the racking. Be sure you know andunderstand all operating procedures and safety precautions.If you have any questions, or dont understand a procedure, please make contact with yourMECA Racking systems expert or speak with your supervisor.

AllMECA

R


Rack System.Shuttle


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heck all items noted in the diagram on page 7-8 each day as you are working in and

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SECTION 2

We recommend you schedule a monthly walk through of your warehouse to check for anydamage, bumps, missing parts or faulty elements to your racking or storage system.MECA recommend you appoint a person responsible for the reporting and checking of yoursystem and put in place an internal procedure for Safety and Risk Assessment reecting yourcompanies standards.

A suggested plan is the have daily, monthly and annual triggers of checking:

DAILY RESPONSIBILITIES OF THE WAREHOUSE MANAGER Ensure a safe and clean working environment C

around your rack. Damaged goods to be handled separately Safety issues to be raised with your Safety Ofce Suspicious areas to be noted for more in-depth checking Inspection of load and information notices specifying safe load capacities.

MONTHLY INSPECTIONS BY WAREHOUSE MANAGER &SAFETY OFFICER

Physical inspections of each bay, column, base and load to ensure weighting and packs arebeing held correctly

Safe working signage is clear and correct Any repairs, faults etc are reported back to MECA



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Figure 6then values for maximum damage shall be specified in the drawings and specification.If the maximum extent of damage assumed in the design differs from that shown ind)

(i.e. actions less action factors), inclusive of pallet weight.actionPermissible working action is to be determined as the unfactored workingNOTE:

If the racking is required to be used in more than one conguration,structuraldrawings shallinclude

distance between first and second beam levels.The maximum distance from base plate level to the first beam level, and the maximumvi)

v) the installation date.acking manufactuer's name, supplier's name and trademark, andDesigner's name.

Permissible working unit load limit.pallet beam level. bay.

to the racking structure at 2.0m above themechanically securedload action figures, written in a large font of at least 25mm high,

corrosion-resistant plaque not less than 125mm long and 250mm high with maximum

acking Solutions comply with all Australian 4084-2012 regulations.

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SECTION 3

GENERAL REQUIREMENTS FOR RACKING INSTALLATIONSMECA R The following isquoted from the Steel Storage Racking Standards of Australia 1.6.

1.6.1 General

To comply with the Australian Standard, a racking shall comply with all of the following:a) The racking installation shall have, in one or more conspicuous locations, a permanent

oor level, which shall contain the following:

R

b)

Load application, racking conguration drawings and specication shall be furnished witheach racking installation. A notice shall be included on the drawings that deviations fromthe drawings may impair the safety of the racking installation.

c)

each required conguration.


i)ii)iii)iv)

Permissible total working unit load limit for eachPermissible total working unit load limit for each


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1Adjustable Shuttle RackingFigure

Shuttle Rack S ystems are engineered to handle only those loads and capacitiesother forms of containment.

orShuttle Rack System are designed to handle oversized single unit loads on pallets

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SECTION 4

The

AllMECAspecied at the time of installation. The rated capacity of each beam is displayed on a signafxed to each beam assembly. No single load should exceed this capacity.



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Figure 2

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SECTION 4

Denitions

Unit load height

Framedepth

Unit loaddepth

Aisle widthbetween upright frames

(a) Side View

Ceiling clearance


Unit load depth clearance

Combined uprightframe depth

Frame height

Unit loadwidth

Row width

Verticalclearance

Unit load

Frame heightVertical

clearance

height Liftclearance

Liftclearance

Ceiling clearance

Ceiling clearance

(b) Front View


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5

SECTION

MECAs products are manufactured and installed for general use in warehouse and storageenvironments and are designed to hold loads and products as outlined in your specication.For optimal installation and for ongoing use of the system, the environment is to have thefollowing elements and tools considered:

FORKLIFTYour forklift, side loader or crane must be suitable for your optimal use of your space and rack.Please ensure your forklift is regularly serviced and checked and can manage the requirements of

your business and warehouse.See the LIFTING section for further information on forklift use.

FLOOR The surface the racking is to be erected on, should be checked and accommodated for thefollowing:

Flatness Surface level tolerance Capable of carrying the specied loads Clean of debris

The load calculation for the oor of the building is the responsibility of the user to ensuresuitability of the intended oor or foundation for the load and theMECA Racking System.The standard load tables take into account that the oor is solid concrete and a minimum120mm thick.

LIGHTINGAdequate and even lighting is to be provided for both the installation team and the ongoingworking conditions of the space.

OPERATORS GUIDE SHUTTLE RACK SYSTEM PAGE 9


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SECTION

OPERATORSYour warehouse/operations personnel are to be trained to operate any of your forklift/machinery,trained in safe working practice and have a good understanding of warehouse management andstorage to ensure a safe work environment.

ENVIRONMENTTemperatureSpecial considerations need to be made for highly humid or damp environments that may vary intemperature from -25C and +40C.

Humidity The extent of humidity needs to be indicated by the user. The variation in temperature is importantto the conditions in regard to condensation forming. For some materials, such as wood,

breboard and internal metal elements, the physical properties may change.Earthquake RegulationsLoads that will sit in Earthquake zones need to be evaluated and racking designed according tothe earth conditions and need to be detailed by the end user.

TO PLAN AND TO SPECIFICATIONYour racking system has been designed, manufactured and installed to your companysspecication. Ensure prior to completion, that your systems set up meets these details.



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Definitions of RackingFigure 3

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S 6

Unit loadA single load that can be placed in one operation. Eg: a pallet in apallet racking system.

Compartment LoadThe load which can be loaded into one compartment of a rack, fromone side.

Bay LoadThe total weight of all unit loads in a bay of the racking, not includingany loads which may be stored on the concrete oor of the bay.

Frame LoadThe frame load is the total allowable weight of all unit loads transmittedto the frame by the beams attached to the frame.


ECTION


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6

Standards AS 4084-2012.

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SECTION

Clear spaceClear spaces around and above each unit load enable input and output of the load withoutcontact with other loads or elements of the rack.

Structural DesignDesign of theMECA Racking Solutions Pallet RStandards AS 4084-2012.

InstallationMECA Racking Solutions use certied installers with minimal operational disruption and withmindful consideration of our OH&S responsibilities. Our team can supply a Safe Work MethodStatement if required.

Pallet Quality It is the responsibility of the user to ensure good quality and suitable pallets are used for thestorage of their product. Weak or damaged pallets must not be used.


acking system is in accordance with Australian


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ProtectionsFigure 4

7

ack system are calculated according to AS4084 - 2012.

consultant.Solutionsbe made to your racking system without contacting your

no changes shouldA change in the rack will generally cause a change in load capacity henceShuttle

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SECTION

The load capacities of a MECA R

MECARacking

SAFETY CONSIDERATIONSIt is the users responsibility to observe regulations and specify the demands for safety protections.The safety requirements depend greatly on local circumstance and need to be aware ofelements like:

trafc intensity aisle width operator discipline use of safety colours load signs good aisle markings overweight pallet unit loads

CORNER, FRONT AND FRAME PROTECTIONSMECA recommend protecting all corners ofthe racking as they are vulnerable to damagecaused by collisions.Front protections and upright protectors willminimise the damage caused by impact loads.



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ng with care by trained people.Pallets must be loaded and picked from racki

loadingShuttle Rack System, the following sequential

SECTION

MECA Racking Solutions recommend the following sequence when placing your load on yourPallet Rack.

The placing of unit loads:1. It is not permitted to place heavier loads in storage equipment than those prescribed by

MECA and shown on the load notices. Additional supporting accessories have to beused properly.2. Load stability: the goods shall be stacked or palletised such that they cant fall.3. Unit load clearances: the actual dimensions of the pallets and goods shall not conict with

the clearances provided for safe operation.4.5. The pallets shall be correctly orientated as specied and properly positioned on the

storage equipment supporting members.

6. Timber pallets must be placed in a rack such that the pallet bearers span the spacebetween beams.7. Pallet shoes to be placed as symmetrically as possible with respect to a pair of pallet

racking beams. In general a normal overhang from the face of the beam of the pallet willbe up to 50mm.

8. Where the lowest pallet in a rack is supported on the oor, a permanent line should bedrawn down each side of each aisle to mark the position at which the front face of thepallet should be placed.

Method of placement:When a pallet is being placed into a MECAactivities take place:

1. The fork lift drives with a pallet to the pallet rack storage location.2. The driver raises and manipulates the pallet into the racking compartment clear of the rack

uprights with no forward tilt of the forks.3. The driver positions the pallet correctly in the depth of the rack with regard to the pallet

rack beams. Before lowering the pallet there is no contact with the beams.4. The driver lowers the pallet carefully onto the beams and releases the load from the forks.5. The driver removes the forks from the pallet and lowers them to the ground.



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Drive - In, Double Drive - In and Drive - ThroughFigure 5

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of contract with the pallet frames.position, keeping the pallet cleardrive forward from the entry to the set downshuttle is then remotely controlled to

he fork lift drives with a pallet to the pallet rack storage location.Shuttle Rack System :

SECTION

The following sequence of placement is to be used for MECAs

1. T2. The driver raises and manipulates the pallet into the racking lane, clear of the rack

uprights with no forward tilt of the forks, at the required storage level and with the palletpositioned centrally between the pallet rails.

3.

4. T

5. The

he driver removes the forks from the pallet, reverses the truck carefully back out of thelane and then lowers the forks.

6. The truck speed is critical for a safe operation. To prevent the mast from exing excessivelyon uneven oors and striking the pallet rails the truck speed must be regulated to suit theoor atness and the mast exibility.

7. The loading and unloading sequence of the loads shall be followed.

4

5

6

7

8

9

10

11

12

Loading12

11

10

9

8

7

5

4

Unloading3

2

1

1

2

3

6

Drive-In and Double Drive-In

UnloadingLoading5

6

3

2

1

5

4

1

2

3

64

Drive-Through


The driver lowers the pallet carefully onto the pallet rails and releases the load from theforks.


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SECTION

ANNUAL INSPECTION BY MECA RACKING SOLUTIONSAn intensive inspection by aMECA Racking Solutions representative and Safety Ofcer to ensureall standards are being met, procedures of care and storage are being followed and anychanges made to the initial and specic installation have been done correctly.If you notice anything of concern, please call yourMECA Racking Solutions representative tocome on site to inspect your area in more detail and to provide you with a solution.Please complete the table below to ensure consistent Safety Audit Inspections. YourMECA representative will also complete the below table on routine visits.

DATEINSPECTIONCOMPLETED BY NOTES ACTIONS



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Examine the out-of-plumb of the racking, refer to ;Figure 6

Figure 6.

withlauses 8.5.

Damage levels shall be specified and a[ppropriate actions shall be taken in accordance

8.3.2

to 8.3.6.lauses 8.3.2

8.3.1

8.3 DA

Examine base plates and floor anchors.h)

8.2 I

section 8:In compliance with Australian Standards AS4084-2012, Section 8, the report states that under

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will require systematic inspections on a regular basis.Shuttle Rack System

YourMECA

NSPECTIONSInspections 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;c) Ensure that the racking installation has not been altered. A copy of the load application

and conguration drawings shall be retained for this purpose;d) Examine the extent of damage due to impact in the racking installation;e)

f) Examine for any dislocation and deformation of sections and connections for uprights andbeams;g) Examine connectors for deformation or signs of cracking the welds.

MAGE DUE TO IMPACTGeneral

The extent of damage due to impact in the racking installation determined from regularinspections and reports of damage incurred shall be assessed in accordance with C

Uprights


C

For uprights, the visible damage shall not exceed that shown in

10SECTION


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acking Solutions.from

r serviceability action specified in Clause4.2.5.When these limits are exceeded, the beam shall be unloaded and advice shall be sought

r serviceability action specified in Clause 4.2.5.vertical deformation undeThe residual vertical deformation when unloaded shall not exceed 20 of the allowedpercent

NOTE: For bracing members less than 1 m long, damage may be assessed pro-rata.

8.3.5 Connectors

8.3.4

8.3.3

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SECTION

BracingFor bracing, the member deviation from a 1m long straight edge in either plan shall not exceed10mm.

Beams

Connectors shall not show visable permanent deformation or signs of cracking of welds.

LET MECA HELPTo arrange a complete maintenance check prior to yourMECA representative contacting you,

please call 1300 661 198.

Direction of rack beams

5.0mm

Direction of frame bracing 3.0mm

5.0mm max.Bend in uprightsection in onemetre gauge length

3.0mm max.Bend in uprightsection in onemetre gauge length

One metregauge length ofstraight edge


50 percent of the allowedThe residual horizontal deformation measured at the top or bottom edge of the beam shall not

vertical deformation unde

MECAR

Figure 6Typical upright section and method of measurement


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nder Australian regulations AS4808-2012, 8.1.3, the racking installation shall not be altered to

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SECTION

Udeviate from the load application and conguration furnished for the racking installation.Physical alterations to uprights, bracing, beams or components, such as welding on additionalcleats or bearers, shall not be made.In addition, change of use, such as from timber pallets to post pallets, shall not be permitted.It is important to call yourMECA Racking representative for assistance on 1300 661 198.



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SECTION

It is recommended that you refer to your forklift supplier manual for safe activity of forklift use,training and damage prevention before operating a lifting truck with aMECA Racking system.Your forklift truck, side loader or crane must be suitable for your capacity, warehouse design andracking conguration. If there are any concerns regarding the usability or suitability of yourequipment, please contact your machine manufacturer to conrm your required use.



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The working load limitFigure 7

13

he working load limit or the total work load limit per bay for the racking installation shalload Limits8.1.2 Working

8.1

As per the Australian Standards AS4084-2012, Section 8, the

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SECTION

Operation and Maintenance ofAdjustable Pallet Racking, the following regulation applies for Safe Working Loads:

GENERAL

LTnot be exceeded.MECA will provide Safe Working loads for the ends of all bays before handing the completedsite over to the user.



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Figure 8Fork truck handling loads

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SECTION

Handle your load with ease, caution and care. Keep a safe warehouse and make sure yourpacks are being loaded and lifted with caution and in correct positions.

DAOLTHGIEW

e C n e t r ao l d pr o i r o t i t f i l n ag d n tr i ll e v a n .g

t t i m i L u r e m e v o m k c nt h t i w r e s i a d ao l d.

i s t i m i L d t f i h s e e p o r o i t a n h t i w

r e s i a d ao l d.

ao l f o p o T d o h s uld n t o e t x e d n k c ab e v o b a r .t s e

ao L d m t h g i e w u t s n e e c x e t o d e m h c at t a n ty i c ap ac t

e m h c at t ae e s nt n .e t al p e m a

FORK TRUCK HANDLING LOADS



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Figure 9

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SECTION

Always close attachment arms beforeattempting to drive through narrow doorways or openings

.

Do not reverse through doorways, racking or around obstructions,with theattachment arms extended

Do not drive foreward through doorways, racking or around obstructions,with theattachment arms extended

.

Check load width before attempting to drive through doorways,or openings.

FORK TRUCK HANDLING LOADS


Fork truck handling loads


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SECTION

Here are some tips to watch out for and to prevent damage or possible accidents in yourwarehouse:

POSSIBLE CAUSE ORPRECAUTION HOW TO MINIMISE DAMAGEHandling Equipment Use correct handling equipment.Storage Correct storage on beams considering weight, load size and

pack type.Truck Drivers Communicate with all drivers and personnel in your warehouse

on use of your racking system.Management Procedures, stock ow and space.Rack Provisions Providing guide rails, rack protections.Warehouse Safety Signage, aisle markings.

Training Ensure all personnel working in the warehouse are trained onuse, safety and your companies OH&S procedures.



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SECTION

How do you know if your damage can be replaced or repaired?It is best to call your trainedMECA Racking representative to come out on site and inspect yourstructure to advise you of any parts that can be repaired or need replacing.



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compliance with Australian Standards AS4084-2012 and all

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This document( Warranty Document) sets out the terms andconditions of the warranty supplied byMECA Racking Solutions( MECA) for the sale ofMECA products and parts to the client. To support MECAs commitment, to the market and ensure

other FEM and world standards for quality. MECA supplies awarranty of ten years (this warranty) (renewable annually asset out below) on all MECA products and equipment which arepurchased by the Client from MECA and installed by registeredtrade installation crews approved by MECA. This Warranty issubject to the following conditions, terms and exclusions.

1. Materials And WorkmanshipDefect Warranty 1.1 In order to retain the benet of this warranty, the Client

must comply with the following:1.2 Throughout the lifetime ofthis warranty , the Client must,

allow MECA or an authorised representative of MECA toconduct an annual inspection of any supplied andinstalled MECA pallet racking or product or part thereof.

Should the Client fail to permit MECA to conduct anysuch annual inspection by MECA, this warranty will beautomatically terminated. It is the responsibility of theClient to contact MECA ofces to schedule the annualinspections to maintain this warranty.

1.3 The Client shall supply MECA with a written noticationrequest for inspection of the site of installation withineach 12 month period from the date of purchase andMECA will then inspect the site as soon as is practicablethereafter. The rst annual inspection will be at no cost tothe Client. In each subsequent 12 month period duringthe warranty period, the client will be charged forinspections at the standard rate for inspections set by

MECA from time to time. Any failure to pay MECA for aninspection will void this warranty.1.4 Once a successful record of annual inspection completed

by MECA has been issued and led with MECA, andsubject to the satisfactory ndings of such inspection byMECA or MECAs representatives (including conrmationby MECA that the maintenance and usage of the MECAproduct and parts by the Client has been in accordancewith all requirements of MECA.) MECA and or therepresentative or authorised agent will supply a certicateof warranty to cover the following 12 month term. If theClient refuses to permit MECA to conduct an inspection,or if an inspection reveals that the client is not using,repairing, or maintaining any of the MECA products orparts in accordance with the instructions and requirementsof MECA, then this warranty will be terminated.

1.5 Without limiting the foregoing any failure by the client toreplace any part or product supplied by MECA that hasdeteriorated due to any normal wear and tear or anyenvironmental conditions or for any other reasonidentied by MECA, then MECA reserves the right toterminate this warranty.

1.6 After each annual inspection has been completed and

the Client has at its cost:a) Purchased from MECA any replacement parts andundertaken all repairs at the cost of the client;

b) Complied with all other requirements of MECA inrelation to the MECA products and parts; and theclient will be issued with a new warranty certicate tocover the following 12 month period;

1.7 Consecutive 12 month warranty is :a) Not transferable and only applies to any new and

previously un-used MECA product or parts that havebeen installed by MECA or authorised MECAinstallation agents.

b) Subject to all of the exclusions, limitations andconditions contained in this Warranty Document.

2. Warranty Against FactoryStructural Damages2.1 Subject to the exclusions, limitations and conditions

contained in this warranty, in the event of any MECAproduct or part structurally failing within the 10 years ofthe date of purchase from MECA; MECA will replace orrepair with an equal or new product and or part with nocharge to the client.a) This warranty is only valid for new and previously

unused MECA parts, and product.b) This warranty is not in any way transferable from the

client to any other user, (unless by an agreement inwriting issued by MECA) and is subject to all MECAwarranty terms and conditions contained in thiswarranty.

c) This warranty will be void if the MECA product orpart:i) Is subjected to misuse, accident, stress or

negligence or if the need for repair orreplacement of the MECA product or part is theresult of any act or neglect by the client or any ofits employees, agents, representatives, or invitees;

ii) Is used for any application other than as speciedby MECA;



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17SECTION

iii) The client fails to adhere to any instructionsprovided by MECA for the use of the MECAproduct or part, including any loading charts forexcess supplied by MECA. This includes anyfailure to comply with the weight load limitationsfor the relevant MECA product as specied byMECA in its loading charts which the clientacknowledges having received prior to the date ofthis warranty;or

iv) any failure by the client to immediately carry outany works or purchase any replacement partsrecommended by MECA, whether after an annualinspection referred to above or otherwise. Uponthe discovery the client or any of its employees oragents of any structural damage or defect of anyMECA product or part thereof, the client agrees toallow any MECA representative or authorisedMECA agent to inspect any such damage orsuspected product failure to the place ofinstallation and to complete its obligations underthis warranty.

3. MECA Product MaintenanceRequirements3.1 This Warranty is recognised for all MECA products and

equipment as supplied by MECA with any moving partsand is conditional, upon the client undertaking at its costall scheduled preventative, maintenance as specied byMECAs service advisors or engineers throughout theperiod of this warranty.

4. MECA Warranty Conditions Agreement Exclusions4.1 Subject to all of the conditions contained in this warranty,

MECAs liability under this Warranty Document is limitedto the repair of a MECA product or part or itsreplacement (if so required in the opinion of MECA) byan equivalent product or part. MECA will not under anycircumstance be liable for any or all direct or indirectlosses, claims, damages, or liabilities of whatsoevernature, including loss of production, loss of market, lossof prot, damages, costs, or expenses of any nature, orfor any nancial or consequential economic loss ordamage that may be suffered by the client or by anythird party; as a result of or in any way connected withany MECA product or part.

4.2 MECA reserves the right to void this Warranty Documentat the unfettered discretion of MECA should the client or

any third party, repair, alter, or modify any MECAproduct or parts without the prior written approval of byMECA.

4.3 If any product or part supplied by MECA is removedfrom an installed site for relocation, then that product orpart must be re-certied by a MECA representative, inorder to maintain this warranty.

4.4 Except as required by law, MECA makes no otherwarranty and provides no representation other than ascontained in this Warranty Document.

4.5 Improvements on any and all products and parts fordesign, materials, and all other improvements are at thediscretion of MECA, and shall not incur any furtherobligations to make any such improvements orinstallations to any already supplied and or existingMECA product or part.

5. Denitions5.1 The original person or party that purchased the MECA

product or service is a client of MECA.5.2 A defect or structural failure is dened as any breaking,

cracking, or collapsing of the MECA product or partwhich is caused by the negligence of MECA.

5.3 All environmental conditions includes chemicalexposure, corrosion, re, explosions, or acts of God.

5.4 Including is not a word of limitation.

Acknowledgement By ClientThe client hereby acknowledges and accepts the terms andconditions contained in this Warranty Document.

Date:

For and on behalf of the ClientName of the Client:

Address of the Client:

ContactsYour MECA Racking representative is:

MECA Operations Manual - Shuttle Rack System

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