I. Installation Preparation and Foundation Acceptance Before construction, a review of the drawings and technical briefings must be completed to clarify the racking's span, shelf height, number of columns, aisle width, and compatibility with forklifts/forklifts. The foundation and site conditions should meet the following requirements: concrete strength not lower than C25, and ground flatness error not exceeding 3 mm/m; select the column base fixing method according to the design, such as embedded parts, secondary pouring, or chemical bolts, and complete the verification. Simultaneously prepare tools and measuring instruments (such as levels, tape measures, and torque wrenches), with the profile cutting accuracy recommended to be controlled within ±0.5 mm; installation must be carried out according to the drawings, and concealed works can only continue after passing inspection before covering. Installation personnel should possess the appropriate qualifications and wear personal protective equipment such as safety helmets, non-slip shoes, and protective gloves.
II. Installation Process and Precision Control
• Columns and Bases: Position and temporarily fix according to the layout. Use a theodolite/level to calibrate, controlling the verticality deviation of the columns to no more than 1/1000. After verifying that the elevation of columns in the same row is consistent, tighten the anchor connections.
• Beams and Shelves: Install from bottom to top according to the floor height, first installing the lower beams and leveling them, then proceeding upwards layer by layer. When using hook-type or bolt-type connections, tighten to the designed torque to ensure reliable locking of the beams and columns, preventing disengagement due to upward external forces. After the shelves/support beams are in place, check their fit with the beams and their levelness.
• Overall Alignment and Tightening: After completing a tunnel or section, perform overall alignment and re-measurement, final tightening and random inspection of all bolts/pins/safety pins; for large-span sections, focus on checking the mid-span deflection and the tightness of connection nodes. • Safety and Protection: Install anti-collision posts/corner guards simultaneously in high-frequency forklift traffic areas; install guardrails/fall-off prevention facilities in high-level areas; demarcate a restricted area during installation, strictly prohibiting unauthorized personnel from entering.
III. Acceptance Testing and Document Transfer
• Document Verification: Review structural calculation sheets, installation plans, material and coating inspection reports, fastener qualification certificates, and change records to confirm consistency with the design.
• Dimensions and Appearance: Randomly inspect the verticality of columns, the horizontality of beams, the height difference within the same floor, and the integrity of the coating/galvanized layer on the component surface; verify that the nameplate and load limit markings are complete and clear.
• Function and Load: Conduct no-load operation checks to confirm the absence of abnormal noises and interference; conduct static load tests (1.2 × design load, static for 24 hours) and dynamic load tests (simulating forklift access) in the presence of the supplier and user, verifying the deformation and connection status of key components; generate video and written acceptance reports and complete signed handover.
IV. Safety Points and Common Mistakes
• Overloading and Uneven Loading are Strictly Prohibited: Unit loads must not exceed the rated load. It is recommended to maintain a safety distance of at least 100 mm between goods and shelf edges to avoid the risk of goods extending out and falling.
• Collision Prevention and Protection: Forklift passage must be subject to speed limits and collision avoidance with uprights; anti-collision and anti-fall devices should be installed around and above the racks, and operating aisles must be kept unobstructed.
• Operating Qualifications: Forklift operators must hold valid operating certificates; non-professionals are prohibited from climbing racks.
• Common errors: Failure to construct according to drawings and insufficient torque leading to loose connections; unverified foundation causing uneven settlement; lack of or failure to install or maintain load limit signs; neglect of fire sprinklers and pipeline clearance, etc., can all significantly affect structural safety and functionality.
