Long, bulky materials stored outdoors are commonplace in UK timber yards, steel stockists, fabricators and builders’ merchants. Cheap yard space means yard capacity can be increased quicker than shop space. However, keeping inventory outside exposes it to the elements and brings risk. Investment should be protected by a suitable cantilever racking system.
Corrosion is the first consideration. Rust can quickly ruin a structurally sound rack in no time at all, especially if it’s left in the yard over the winter in the UK. A rack that performs well in a dry, covered warehouse may only last a few years out in the elements. Coastal yards present an even greater challenge due to the corrosive nature of sea air. For permanent outdoor situations, hot-dip galvanising is the preferred racking finish. For sheltered situations, such as under a canopy, paint or powder-coat finishes may be an economical solution. However, any chips in these coatings should be touch-up painted to prevent corrosion.
Ground conditions are the second consideration. A cantilever rack carries the entire load of the shelf through the base of the upright. To support this, the base of the upright requires a good bearing surface. Point loads can cause settlement and deformation in the ground, especially after heavy rains. A reinforced concrete slab of sufficient thickness and strength, confirmed by a structural engineer, may be required. Drainage should be considered, as standing water can create an even greater corrosion problem.
Wind loading is often overlooked. Fully loaded racks are relatively stable, but wind can impact empty or partially loaded arms, and sheeted loads act like sails. Uprights should be correctly braced and anchored, and the layout should take into account the exposure of the site. Where the exposure is high, a canopy or other roofed structure can help, although this also changes the loading calculations and should be included in the overall design.
The other side of the equation is the protection of the stock itself. Some materials can warp or stain, for example, timber can stain or warp, and some metals can discolour. Using a canopy or other roofed structure, as described previously, will keep stock dry. Consider how the stock is separated. Arm spacing should be wide enough to allow for free movement of air, which will avoid rain and/or moisture from collecting on the stock.
The same careful consideration for designing handling equipment and traffic routes should be given to designing outdoor yards. The width of yards should be the dimension that will accommodate the largest and longest loads, and surfaces should be even and dry, so that the forklift operator can manoeuvre loads safely. Guarding should be provided at the ends of runs to prevent pedestrian and forklift collisions, and to contain loads.
Inspections and maintenance should be part of your routine from day one. The Provision and Use of Work Equipment Regulations stipulate that employers keep work equipment, including storage equipment, in safe condition. According to industry guidance, such as the SEMA Code of Practice, storage equipment should be regularly inspected, and the results of those inspections documented. For outdoor rack storage, inspections should include base plates and arms for signs of corrosion and movement, and fixings for signs of looseness. Locking pins should be checked to ensure they are secured and load notices should remain legible. A trained person should carry out inspections on a regular basis, with a more detailed expert inspection performed at least once a year.
Capacities and load notices are of great importance. The rated capacity of each arm and upright should never be exceeded. If the type of material being stored is changed, or if new arm levels are added, a review of the revised arrangement should be undertaken to ensure the safe working loads displayed are still applicable.
Consider long-term value. Well designed outdoor storage systems can last a business decades. The systems are moderate to low maintenance. Cheaper systems, that may seem like a better short-term value, can require major maintenance or even replacements in a few short years. This can disrupt business operations and actually cost a company more than what they saved with the initial purchase.
Planning to store long, heavy or awkward items in your yard? Take the time to specify a storage system to your site conditions, the types of loads you wish to store and handle and the equipment you will be using to do so. Working with a knowledgeable supplier during the design phase can ensure your racking is compliant, safe and able to withstand the British weather.