I. Standard System and Scope of Application The entire lifecycle of large-span storage racking should simultaneously meet the requirements of national standards, industry standards, and operating procedures. The core standards include: GB/T 27924-2011 Industrial Shelving - Dimensions and Rated Load Capacity, and GB/T 28576-2012 Industrial Shelving - Design Calculations, for design calculations and rated values; WB/T 1066-2017 Technical Standards for Shelving Installation and Engineering Acceptance, for installation and acceptance; GB/T 3454-2016 Specifications for the Use and Operation of Storage Shelving, for use and operation; and type-specific standards such as WB/T 1044-2012 Pallet Racking, WB/T 1074-2018 Gravity Flow Racking, WB/T 1075-2018 Cantilever Racking, WB/T 1076-2018 Cold Storage Racking, and WB/T 1077-2018 Shelving, for automated storage and retrieval systems (AS/RS) and steel structure racking, GB/T 39830-2021 should also be referred to. The design specifications for seismic resistance of steel frame storage racks in automated warehouses include JB/T 5323-2017 and JB/T 11270-2011. These standards collectively form a closed-loop compliance framework from design, manufacturing, installation to use and maintenance.
II. Key Points for Design Phase
• Loads and Rated Values: Based on the actual weight of the cargo unit, pallet/container dimensions and distribution, and inbound/outbound frequency, determine the design loads, safety factors, and load combinations; rated values and loading methods must be consistent and clear in the design documents and on-site markings.
• Structural Calculations and Deflection Control: Perform strength and stiffness checks on large-span beams, control mid-span deflection and node deformation, and ensure that stability and deformation limits under full load and off-center load conditions meet the specifications and the company's internal control standards.
• Stability and Seismic Resistance: Considering the seismic zoning of the warehouse area, wind load/ground conditions, and equipment dynamic loads, install lateral supports, wind-resistant bracing, and node stiffening as necessary. Overall stability calculations should be performed for high-level and long-span layouts. • Terminology and Classification: WB/T 1042 warehouse racking terminology and WB/T 1043 warehouse racking classification and numbering shall be uniformly adopted to ensure consistency in design, manufacturing, installation, and operation and maintenance.
• Specialized Racking: For specialized racking such as pallet racking, gravity flow racking, cantilever racking, shelving racking, and cold storage racking, the additional structural and performance requirements of the corresponding product standards shall be met.
III. Key Points for Manufacturing, Installation, and Acceptance
• Manufacturing and Materials: The material, dimensions, coating/galvanizing quality, and corrosion resistance of components shall conform to the design and standards; the performance grade and fastening process of connecting parts (such as high-strength bolts) shall meet the drawings and specifications.
• Installation Control: Construction shall be carried out according to the approved design drawings; the connection between the anchor and foundation shall be reliable; the verticality of the uprights, the horizontality of the beams, and the height difference within the same floor shall meet the acceptance standards; the connection nodes shall be finally tightened in place, and the torque shall be randomly checked. • Data Handover: Complete design calculations, manufacturing and inspection records, installation plans and concealed works acceptance, fastener qualification certificates, coating/galvanizing inspection reports, nameplate and load limit label lists, etc.
• Acceptance Testing: In addition to dimensional, appearance, and label verification, functional and load verification (e.g., static load, dynamic load/access simulation) should be conducted, and a written acceptance report and video recordings should be generated as the baseline for subsequent use and maintenance.
IV. Key Points for Use and Maintenance
• Activation Conditions: The racking can only be put into use after passing acceptance; any modifications, relocations, or adjustments to the loading method must be approved in writing by the designer/supplier.
• Labeling and Training: Rated load and loading method labels should be prominently displayed; forklift operators must be certified, and all personnel must complete racking safety and operating procedure training.
• Operating Procedures: Overloading and uneven loading are strictly prohibited; necessary clearance must be maintained between goods and shelf/beam edges; aisles and work areas must be kept clear; forklift speed limits must be enforced, and collision avoidance columns and corner guards must be installed.
• Inspection and Maintenance: Establish a three-tiered inspection mechanism: daily, periodic, and annual. Daily inspections are conducted by operators; weekly/monthly inspections are conducted by safety managers with reports submitted; and a comprehensive inspection is carried out by professionals every 3-5 years. Closed-loop rectification and retesting are implemented for potential hazards such as collisions, deformation, loosening, and coating damage.
V. Testing and Third-Party Services
• Testing Types: Includes installation acceptance testing, in-use condition testing, specialized testing (load-bearing/deformation/connection/corrosion protection), and annual safety assessments, covering key items such as component integrity, connection tightness, column verticality, beam deflection, anchors and foundations, safety clearance, and protective facilities.
• Frequency Recommendations: Determined based on factors such as forklift activity, equipment type and quality, personnel skills, rack type and damage history, floor conditions, and ambient temperature. It is generally recommended that a specialized third-party conduct a specialized inspection and generate a report at least once a year.
• Suggested methods: On-site methods include non-destructive testing, geometric measurement, torque verification, and coating/galvanized layer inspection. The industry generally uses national/industry standards as the basis for judgment, and can further refine the evaluation system by referring to internationally accepted practices such as EN 15635, EN 15629, and EN 15620.
