Improving Ergonomics, Reducing Injuries

Every year back injuries coast American industry $14 billion in worker compensation payouts. 30% of workers compensation claims are related to material handling incidents. By following the ergonomic guidelines below you can increase productivity and reduce worker injuries.
Reduce Bending Motions Use lift tables, power lifters, and other mechanical assists. Raise work level to height of worker. Provide all material a work level. Don’t lower anything to the floor that must be lifted later.
Lift tables reduce bending motions while increasing productivity. Visit Materialflow.com for a large selection of lift tables.

Reduce Twisting Motions Put all tools and materials in front of the worker. Use conveyors, chutes, and slides to change direction of materials. For seated workers use adjustable swivel chaires. Give workers enough room for their whole body to turn. Improve layout of work area.
	Work Positioners can rotate materials, reducing twisting motions for workers.

Reduce Reaching Motions Eliminate horizontal reaches of over 16″. Put machine controls and tools as close to the worker as possible. Place materials and workplaces close to workers. Reduce size of material being loaded, allow worker to easily position materials with a pallet positioner, or lift table. Keep objects close to body.

A scissor lift keeps objects close to the worker and reduces reaching and other hazardous movements.

Eliminate manual lifting and lowering Use lift tables, hoists, balancers, drum handlers, dumpers and other lifting equipment.

Reduce weight of objects Reduce size of objects being lifted. Reduce weight of containers. Reduce number of objects being lifted.

Increase weights of objects and use mechanical equipment Use bins and containers with fold down sides in place of smaller containers. Use palletized loads.

Reduce Hand Distance Use grips or handles. Provide scissor lifts, turntables, and tilters.

Reduce the need to pull and push Use powered conveyors. Use powered trucks. Use drum handlers, dumper and rotator.
Reduce required pushing/pulling force Reduce weights of loads. Use gravity conveyors, or ball bearing conveyor systems. Maintain floor surfaces and provide handtrucks, dollies and portable lifters.
	Powered conveyors eliminate the need for workers to push and pull prodcuts.

Eliminate the need to carry objects Conveyors, ball caster tables, and other equipment eliminates the need for workers to carry products long distances. Lift trucks, hand tucks and dollies make moving akward objects easy.
Reduce Weight of Objects Reduce size of objects if possible. Reduce capacity of containers. Reduce weight of containers.
	By reconfiguring your storage bins you can reduce weight and worker injury.

Things to Consider Before Purchasing Pallet Rack

Purchasing a pallet rack system is a big investment. The guide below outlines several considerations to make before purchasing a rack system. For more information visit Materialflow.com or call 1-800-338-1382

1. Responsibility between lift truck and rack system. Who will take it?
2. Is there enough aisle spacing to operate the truck? Pallet rack is one thing; drive-in rack requires another aisle spacing. Pushback and pallet flow rack take up to 1′ 6″ more aisle space than pallet rack. Because the truck must go straight in and out of the system, the operator can’t begin to turn into the load before being straight in front of it.
3. 95% of all rack collapses are due to operator error. Abuse is just like a car. Sometimes it is driven off the lot and totaled within one day, sometimes the car never gets into a wreck.
4. Know your loads by weight. Don’t guess. Overloading can be a real problem.
5. Be honest about your operators. If you already have rack abuse you will continue to have it. Ways to change this pattern: A) additional training, B) wider aisles, C) cutting cross aisle traffic down.
6. Design from the inside out, not the other way around.
7. Look at your competitors’ facilities. Not all companies are the same.
8. Anybody can sell rack. New or used. But what do you get? Is it the right height, depth or type?
9. Don’t buy a piece of lift equipment before you buy your rack system. Remember lift truck houses sell lift trucks because that is what they are supposed to do, just like a car dealer.
10. Everybody wants their product like Burger King. They are in such a rush to get it off their desk that they many times make a mistake. For some reason there always seems to be enough time to get it corrected but not enough time to do it right in the first place. Remember to allow enough time to plan, don’t rush.
11. When should you replace a rack? A) Broken welds on upright, B) Beams creased or bowed in, C) Column off of footplate.
12. A pallet should overhang a beam by 3″ front and back in order for the stated capacity to be valid, otherwise the capacity has to be down-rated.For more information visit Materialflow.com or call 1-800-338-1382

Material Handling Safety

According to The Materials Handling Handbook, “nearly one fifth of industrial accidents are related to material handling activities”. Lifting and and manual effort are a major contributor to on the job injuries. By using mechanical or automated equipment the amount of injuries and accidents can be reduced. Proper safety measures don’t just save lives, they save money and reduce downtime caused by injuries. While new equipment is helpful in reducing injuries it can often create a new set of dangers. The guide below outlines some safety features to look for when buying equipment as well as some tips for safely operating it.

Conveyor Safety

Prevent pinch points that exist when belt conveyors are permanently attached to other conveyors. Use connector brackets with safety pop out roller (other stationary equipment will require proper guarding and safety devices.)

Rack System Safety

Rack systems should only be assembled by trained personnel who have experience with rack assembly. -Do not used beams with damaged or missing safety locks. -Do not install racks outdoors unless they are specifically designed for this purpose. -Never climb on racks during or after assembly. -Install capacity plates and do not overload racks.

Lift Tables and Tilters Safety

Make sure lift tables and tilters are equipped with beveled or electric toe guards. Never exceed rated load capacities. Use accordion skirting as it covers internal components and prevents pinching and damage to the table itself. A velocity fuse will prevent lifts from falling if a hose becomes severed.

Misc.

Matting can prevent slips and falls in the workplace while reducing worker fatigue.

Visit www.materialflow.com for a huge selection of material handling equipment.or call 1-800-338-1382 for expert customer service.

Cascade Storage Rack Manual

In order to get the most from you storage rack system it is imperative that the rack is properly assembled and maintained. The information below will assist you with your responsibility of providing a safe storage rack system. Contact Material Flow at 1-800-338-1382 for more information.

Storage racks should only be assembled by trained personnel who have experience with rack assembly.

Improper rack assembly can reduce efficiency and pose safety risks. If you are not familiar with rack assembly you should contact Material Flow for professional assembly. Material Flow cannot provide or guarantee warranty services if your rack is assembled improperly. Call us at 1-800-338-1382.

It is imperative that rack structures are installed on a plumb, level, and square fashion. Since most floors aren’t perfectly flat shims are often required. A four foot long carpenter’s level is great for checking level and plumb specs on a storage rack of reasonable size. A vertical tolerance of 1/8” in 4 feet is generally acceptable. (Building code for floors is + or – 1/8” in 10 feet.) Changing configurations (such as adjusting storage levels) can adversely affect load carrying capacity and structural integrity of the rack system. Before adjusting rack configuration contact Material Flow to double check the safety and structural soundness of the new configuration.

“Nut and Bolt” connections are to be tightened to a snug and secure condition. 60 foot pounds is recommended for ½” diameter hardware. Avoid tightening components to the point of crushing.

Safety locks on bolt-less connections must be fully engaged through the beam connector and upright column connector holes. Safety locks help prevent accidental dislodgement of the load beams. Locks should engage automatically; however, the beam needs to be fully seated in the bottom of the teardrop shaped connector hole.

Do not use beams with damaged or missing safety locks. Contact Material Flow for extra safety locks.

Every Column of each rack frame must be anchored to a sufficient concrete floor. A normal anchor connection is on ½” diameter X 5 ½” or as indicated on the Material Flow installation drawings. (3 ½” embedment is code.) Anchor bolts are not included with our rack systems unless detailed on the invoice. Because concrete floors can vary greatly in design and load capacity Material Flow cannot guarantee that a specific concrete slab is suitable to support a particular rack installation. The characteristics of the slab should be obtained from the building’s architect before the racks are ordered to ensure the proper rack for the specific slab.

Racks are not to be installed outdoors unless specifically designed by Material Flow for this purpose. Outdoor usage requires consideration of winds, snow, and other variables not normally considered in rack design.

Be cautious when mixing new and existing parts. Components from the same company can vary in design. Manufacturers often modify basic designs over the years to improve performance. These differences can affect safety and lead to dangerous situations. While it may be possible to assemble a rack system with parts from different manufacturers Material Flow can only warranty and guarantee systems built with genuine Cascade parts.

Installation of capacity plates is highly recommended. These plates specify load size, load weight, and rack configuration. These plates communicate important safety information for both present and future users. Several signs should be posted to maximize visibility. Signs can be procured through Material Flow.

Never climb on racks during or after assembly. Storage racks are not designed to be stepped or climbed on. Serious injury may result from doing this. It is your responsibility to communicate this warning to those who use and come into the area of your storage system. Prominently placed signs are very helpful, especially if your rack is in a retail environment.

Allow adequate aisle spacing. Aisles that are too narrow for handling equipment increase the danger of collisions between lifting equipment and rack structure. Collisions can result in items falling or broken products.

Maintain sufficient clearances around loads. These include clearances dictated by fire codes (between loads in back to back rows and overhead between top load and ceiling structure). Also between adjacent loads horizontally and between loads and rack horizontal and vertical members. Tight clearances decrease handling speed, increase fire risk and the likelihood of damage to rack systems.

Install good lighting in every rack aisle. Good lighting improves handling efficiency, prevents accidents and reduces damage to rack systems.

Install optional column protectors at aisle facing columns, and guard rails at ends of rack rows. These devices provide a physical and visual barrier against handling equipment impacts. Material Flow has a large selection of these devices.

Do not cut, weld or in any other way modify any component of your Cascade storage rack. These modifications can jeopardize the structural integrity of your rack structure. Any modification except performed or authorized in writing by Material Flow personnel will make null and void any warranties and guarantees.

Use only high quality pallets. Broken, cracked, or poor quality pallets can cause falls from racks, or cause dynamic racks to become jammed or inoperable.

Perform regularly scheduled inspections and maintenance at least once a year.
Inspect:
All hardware for tightness (including anchors)
All beam safety locks for operation and engagement
All racks plumb, square, level
No dents, knicks, or damaged components
Load sizes and weights match original specs.
Check finish, touch up chips or scratches to prevent corrosion

Replace damaged or missing beam safety locks immediately! Do not use beams without safety locks. Unload damaged racks immediately and contact Material Flow for replacement parts.

Minimize contact between storage racks and handling equipment. This is the key to improving rack longevity. Educate rack users to avoid dropping loads onto rack, how to position material correctly and how to report rack damage.

Do not overload any rack system or component. Storage racks are designed for specific weights. Should your load weight requirements change contact Material Flow before using the rack for new loads. Overloading racks can result in damaged material and severe injury.

Other Precautions: When using a fork truck be sure that the truck is equipped to protect the operator from accidental crushing against storage, rack loads, or other objects. If your fork truck lacks these features contact the manufacturer/reseller of the fork lift equipment and get the proper safety equipment installed.

Make sure that your fork truck is equipped to protect against accidental falls. Platforms where operators stand must be approved by the manufacturer and OSHA. Operators should always be restrained and protected from falling off equipment.

Keep work area clean. Keep aisles clear of trash or obstruction. Do not stack pallets on floor, keep floor surfaces clean and free of moisture.

Questions about Cascade Rack?
Material Flow & Conveyor Systems
800-338-1382 or 503-684-5133
11117 SW Greenburg Road
Tigard, OR 97223

Cantilver Rack: A Quick Overview

Cantilever rack is great for storing steel bars, lumber, and pipe. Long, heavy items are stored with ease. The main benefit of Cantilever Rack is increased accessiblity to loads. Forklifts can easily load and unload from rack arms and base. Another benefit of cantilever rack is that it is easy to add additional arms, uprights or braces as storage needs change. For more information on a cantilever rack system call Material Flow at 1-800-338-1382 for expert assistance. There are three main parts to a cantilever rack system. Uprights Uprights are made up of a vertical column and a horizontal base that is bolted to the column. It requires at least two uprights to build a cantilever rack storage system. The edges of the vertical column are punched (sometimes on both sides) so they can be used as a double sided upright depending on the size of the base being used. Arms Cantilever arms are the most important piece to a cantilever rack system. Straight arms are generally used for storing stable loads such as lumber sheets. Inclined arms are used for goods that tend to roll forward such as pipe or tubing. Arms are adjustable up and down depending on storage requirements. Braces Braces are what hold a cantilever rack system together. Bracing for uprights is based on the height of the uprights being used. Proper bracing is important as it provides rack stability. Designing a Cantilever Rack System Knowing what you are going to store on you cantilever rack system is the most important factor in cantilever rack design .It is important to keep in mind the weight, length, depth and height of the product you are going to store. Spacing and Arms Deflection occurs when arms are overloaded. When deflection occurs arms can be bent and products dropped. An easy way to find deflection is to place a load over two wooden blocks. If there is no deflection a simple two arm cantilever system will work. If there is deflection a three or four arm system is needed. The drawings below show how to test for deflection with two, three or four arm cantilever rack systems. The load should overhang the arm ends by one-half the distance from upright centerline to upright centerline. Length of Arms It is important to never exceed the length of a cantilever arm with a product. A 60″ wide sheet of wood requires a 60″long arm and so on. By loading materials properly you can get the most out of your cantilever rack. The guide below shows the correct and incorrect loading techniques. All of these arm capacities are based on an evenly distributed load. It is also possible to center a load on the centerline of the cantilever arm. Call Material Flow at 1-800-338-1382 to purchase a well designed cantilever rack system. Height of Uprights Things like forklift reach, ceiling height and building codes all have an impact on the height limit of your cantilever systems height. Upright height often depends on the rack system being used. Call the experts from Material Flow at 1-800-338-1382 for more information on cantilever rack or pallet rack systems. Arm and Upright Capacities A simple formula for calculating required arm capacity is by determining the number of arms per level and dividing it into the weight per level. Determining the required capacity of each upright is accomplished by multiplying the number of arms per side by the load on each arm. In the image below each arm holds 2000 lbs. Total capacity for all twelve arms is 24,000 lbs. Divide this 24,000 lbs by three uprights and the required minimum capacity per upright is 8,000 lbs. Arm Capacity Should Not Exceed Total Upright Capacity. For professional assistance call Material Flow at 1-800-338-1382 or visit Materialflow.com They have the largest supply of cantilever rack on the west coast, friendly customer service and years of experience in pallet rack system design.

Examples of Specialized Pallet Rack

In addition to standard pallet rack systems there are many specialty racking systems available. These racks are great for specific products and high flow situations. Read the guide below for more information on these specialty racks.

Flow Racks Flow racks allow products to flow from back to front. When loaded properly the oldest inventory is removed first. Thanks to their clever design they can increase productivity and reduce worker fatigue. These racks are available in several specialized configurations including: pallet gravity flow, greenhouse gravity flow, hospital gravity flow, and mobile flow. These racks are great for high flow applications where inventory is quickly coming in and going out.

	Drum Pallet Racks
	Drum Pallet Racks are designed to store high capacity 30 and 55 gallon drums. The great thing about these racks is that the drum cradles are removable, allowing standard pallets to be used if desired.

Backstock Racks Backstock Rack is one of the most economical storage solutions. It’s great for storing bulky products and the high strength steel beams with wood decking ensure durability.

Tire Racks This tire rack is designed to keep tires organized and out of the way. Perfect for service shops, car dealerships or even an auto enthusiast’s garage.

Cylinder Pallet Racks These pallet racks safely secure and store cylinders. This unit features fork pockets and access to individual cylinders. Casters are also available. Perfect for storing those loose helium containers.