EOHS Number 03-001

EOHS Standard Issue Date: 6/30/03

Title: Rack Design and Maintenance Supersedes Date: None
Author: EOHS Effective Date: 6/30/03

TABLE OF CONTENTS

1. Purpose ...................................................................................................................2
2. Scope ......................................................................................................................2
3. Definitions................................................................................................................2
3.1 Base Plates .......................................................................................................2
3.2 Flue Space ........................................................................................................2
3.3 High Intensity Lighting Discharge System.......................................................... 2
3.4 Load Beams ......................................................................................................2
3.5 Pallet Load ........................................................................................................2
3.6 Pallet Safety Stops ............................................................................................ 2
3.7 Pallet Slot ..........................................................................................................3
3.8 Rack Leg Deflectors .......................................................................................... 3
3.9 Rack Uprights....................................................................................................3
3.10 Reinforced or Double-Posted Uprights ............................................................ 3
3.11 Roll-Formed Rack............................................................................................ 3
3.12 Structural Rack ................................................................................................ 3
4. General Requirements – For Installed Rack Systems..............................................3
4.1 Design Considerations....................................................................................... 3
4.2 Operation...........................................................................................................5
4.3 Maintenance......................................................................................................5
5. Training ...................................................................................................................6
5.1 Personnel Assigned to Inspect Racks or Perform Rack Maintenance................ 6
5.2 Fork Truck Operators......................................................................................... 6
5.3 Documentation ..................................................................................................6
5.4 Re-training.........................................................................................................6

Colgate Palmolive Company Confidential for Internal Use Only Page 1 of 6

EOHS Standards are not intended to replace local, regional, or national regulatory requirements. The Standards should be viewed as a
separate requirement, and facilities should achieve whichever requirement is higher. EOHS Guidelines are for advice,
recommendation, or illustration only.
EOHS Standard EOHS Number 03-001

Title: Rack Design and Maintenance Issue Date: 6/30/03

RACK SYSTEM DESIGN AND MAINTENANCE STANDARDS

1. Purpose

To establish performance requirements for the durability and integrity of new and existing
rack systems, as well as for periodic maintenance including inspections, identification and
reporting of damage and repair of existing rack systems.

2. Scope

This standard applies to Colgate-Palmolive and subsidiary locations, including both

manufacturing facilities and warehouses operated by Colgate-Palmolive, where racking has
been or will be installed.

3. Definitions

3.1 Base Plates

Square or rectangular plates, used under each vertical member, that provide an anchoring
medium and load distribution. The size and thickness of a base plate will depend upon the
specific site and application.

3.2 Flue Space

The space between back-to-back rows of pallet racking. This space should be sufficient to
allow for building columns or other possible obstructions and permit the desired amount
of pallet overhang.

3.3 High Intensity Lighting Discharge System

A lighting system capable of emitting a very high number of lumens per watt per lamp
utilizing halogen, argon, etc.

3.4 Load Beams

The horizontal member of the rack structure that carries the static weight of the load
itself. Each pallet load should have two load beams supporting it, front and back.

3.5 Pallet Load

The product placed on a pallet defines the product load. It should not overhang the edges
of the pallet, if possible. This will help alleviate product damage while handling full
pallets with forklift equipment.

3.6 Pallet Safety Stops

A device installed on the rear pallet support beam in a racking system to prevent a pallet
from being inserted too far into a location. This device helps maintain a consistent flue

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EOHS Standard EOHS Number 03-001

Title: Rack Design and Maintenance Issue Date: 6/30/03

space between back-to back rows of pallet racking, and prevents the possibility of a pallet
falling from the back of a single row of pallet racking.

3.7 Pallet Slot

A location within a rack storage system designed with appropriate dimensions to
accommodate a single pallet load

3.8 Rack Leg Deflectors

Durable protective devices constructed of steel that are installed on the front of the
upright legs that face the aisle. They are placed just above the base plate to allow the
forks from a lift truck to be diverted from the upright if struck, thus limiting the amount
of damage incurred.

3.9 Rack Uprights

The vertical structure that supports the pallet load support beams on each end and forms a
bay of rack storage. The construction and dimensions of the upright can vary based on the
weight capacity required.

3.10 Reinforced or Double-Posted Uprights

This design uses two uprights welded together to give added protection and strength to
the lower part of the upright.

3.11 Roll-Formed Rack

This type of racking is constructed from cold rolls of steel. It is unrolled, slit into proper
width, then rolled and formed into tubular or “C” shapes. Installation of components is
accomplished by a slotted connection with a locking pin placed behind the connection, to
ensure a secure fit.

3.12 Structural Rack

This is a rack that is constructed by rolling hot steel into structural shapes. Rack uprights
and support beams are constructed in a “C” shape. The installation of the rack system is
done with bolts and nuts.

4. General Requirements – For Installed Rack Systems

4.1 Design Considerations

4.1.1 Rack design should be either structural rack or roll-formed.

4.1.2 Rack uprights should be continuous without splicing, i.e., welding, bolting.

4.1.3 All racking should be securely bolted to the floor.

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EOHS Standard EOHS Number 03-001

Title: Rack Design and Maintenance Issue Date: 6/30/03

4.1.4 There should be no visible deflection of the base plate. The rack upright
should be adequately secured and balanced as not to create uneven forces on the
base plate. The base plate should show no distortion from mechanical impact,
such as from forklifts.

4.1.5 All rack uprights and load beams should be designed with adequate
structural capacity to support the anticipated loads. Documentation should be
available supporting the design.

4.1.6 Signage indicating maximum weight capacity should be provided on all

racks installed for storage of raw materials to prevent over-loading of racks.
Similar information should be maintained for finished goods storage racks in a
file that is readily available.

4.1.7 Racking systems should include the following design considerations:

 Reinforced or double-posted uprights

 Rack leg deflectors

 Wire mesh decking or pallet support bars (in areas with high levels
of pedestrian travel or overhead storage cross aisles)

 “End of Aisle” upright protection

 Pallet Safety Stops

4.1.8 Racking and pallet heights should not obstruct lighting. Lighting should not
be installed within racks.

4.1.9 Work aisles between rows of pallet storage racking should be of sufficient
width to allow equipment to maneuver safely during the course of performing a
work task.

4.1.10 The pallet slot should be designed to accept one pallet, based on the height
of the pallet load. Pallets should not be stacked within a pallet slot, even if space
permits.

4.1.11 If a High Intensity Discharge lighting system (HID) is installed, the

fixtures should be protected by covers. Combustibles should be kept at least one
meter from any part of the HID fixtures.

4.1.12 Racks should not be attached to the building structural systems, (e.g.,
walls, columns), unless the building structure is designed to support the load.

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EOHS Standard EOHS Number 03-001

Title: Rack Design and Maintenance Issue Date: 6/30/03

4.1.13 Rack heights should be such as to allow adequate clearance (i.e., one
meter (36 inches)) for sprinkler systems from the top of the highest supported
load to the sprinkler deflector.

4.1.14 Rack beams should be provided with a locking system to prevent

disconnection of beams from uprights.

4.1.15 Nothing should be hung or attached to racks, (e.g., cable trays), with the
exception of in-rack sprinklers.

4.1.16 All installations should be completed by a qualified, reputable engineering

firm.

4.1.17 Any modification to an existing, installed rack system should be subject to

a Management of Change review. (see 1996-022, EOHS Standards for
Management Systems, 3.3.2)

4.2 Operation

4.2.1 Only pallets of adequate strength should be used.

4.2.2 Unused idle wood pallets should not be stored/stacked within pallet slots.

4.2.3 Product or pallets should not be stored in aisles between racks.

4.2.4 A system should be in place to manage damaged pallets.

4.2.5 Portable racks, (e.g., V-racks), should not be used.

4.2.6 Racks installed over aisles or passageways should be marked to warn fork
truck drivers of height constraints.

4.3 Maintenance

4.3.1 Documented inspection of racking systems should be conducted at least

monthly. The inspection should include, but not be limited to, a visual check of
the rack system to identify damage, missing components, plumbness of uprights
or other potential problems.

4.3.2 When in-rack sprinklers are installed, ensure that pallets do not obstruct the
sprinkler.

4.3.3 Where earthquake bracing is installed, it should be inspected and

maintained according to the manufacturer’s specifications, (e.g., cross-bracing).

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EOHS Standard EOHS Number 03-001

Title: Rack Design and Maintenance Issue Date: 6/30/03

4.3.4 A follow-up procedure should be established to address all noted

deficiencies. Corrective actions should be tracked to closure. Documentation
should be maintained.

4.3.5 A rack that has been structurally damaged should be emptied of the storage
contents until such time as corrective measures have been taken. The pallet slot
should be marked, (e.g., taped), to prevent stock from being placed on the
damaged rack. If the warehouse has a Warehouse Management System (WMS),
that storage location should be blocked in the system electronically.

5. Training

5.1 Personnel Assigned to Inspect Racks or Perform Rack Maintenance

All personnel assigned to inspect racks or perform rack maintenance should be properly
trained in the techniques and procedures to inspect and repair rack systems.

5.2 Fork Truck Operators

All fork truck operators tasked to store or retrieve materials from rack systems should be
trained for the specific type of rack installed and the associated material handling
equipment.

5.3 Documentation
All training documentation should include the person’s name, department, date of
training, and subject of training.

5.4 Re-training
Re-training should be scheduled in accordance with 1999-087 Materials Handling, 5.4.2.

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