Racks are warehouse structures that are used to store various materials, goods and equipment. The safety of the personnel serving them depends on their quality. In the event of a structural collapse, the loss may amount to thousands, millions of rubles. To prevent the negative consequences of violation of the integrity of the nodes and elements of the system, periodically tested racks.
There are a number of features of a similar process. Different techniques are applied. How the process of testing the strength of structures is organized and carried out will be discussed later.
The need for verification
Testing shelving (GOST 55525-13) is made for a number of reasons. First of all, when creating a new design, certain errors may be present when casting its elements. In this case, the structure will not be able to withstand the intended loads.
To avoid destruction of the structure, the manufacturer tests the objects created by him. At the same time, he fixes the facts of miscalculation during the technological cycle. Errors in the drawings are eliminated.
Also, the manufacturer must establish compliance with the actual parameters of the rack declared characteristics. This allows you to prevent an accident during the operation of the facility. In this case, it is possible to significantly reduce the likelihood of not only the occurrence of economic damage, but also injuries or even death of warehouse employees. This is one of the most effective conservation measures.
What time is the verification carried out?
Instructions for testing racks involves testing in four main cases. The first time such testing is carried out in production. When a new structure is created according to new drawings, a test structure is made. It is subjected to testing to identify development errors. If all the requirements are met, the product goes into mass production.
After manufacturing a batch of similar systems, several test units are selected from them. If the characteristics of the warehouse equipment meet the standards, all created products go on sale.
Before installing racks, their storage conditions are checked. After installation, the strength of all joints of each shelf and support is also tested. During operation, the product is also periodically checked. The approximate frequency is once every two years. This procedure is carried out until the structure is written off from the balance sheet of the company.
What does the check pay attention to
There is a certain list of issues that inspectors pay attention to. The results are documented. For this, an act of testing racks is issued, a sample of which is presented below.
Deviations from the horizontal, vertical level of racks and beams are investigated. At the same time, the features of storage racks are necessarily taken into account.
The error in the deviation of the cross-sectional index of the bearing elements is determined. Such deviations provoke very high loads. Researchers must also evaluate the appearance of beams, racks, shelves, pallets.
It is important to pay attention to the integrity of the seams remaining after welding, or threaded connections (with bolts). Tests compliance with the standards of the step of placing bearing supports and rungs. At the end of the check, the compliance of the shelf capacity indicator with the characteristics stated in the passport is established.
Visual inspection
After the inspection, the manufacturer and the user must draw up an act of testing the shelving. It indicates the data of the studies. This is an official document, the design of which is regulated by the relevant standards.
To understand the entire verification procedure, it is necessary to consider the stages of its implementation in more detail. First, a visual inspection is performed. The examiner evaluates the quality of the materials. He must inspect the surfaces of all elements for defects. The protective layer, which prevents the material from destruction, must remain intact. It should not be chipped or scratched.
After that, the geometry of the beams and support columns is evaluated. Their meaning should be in line with standards. If there are traces of oxidative reactions on the surface of metals, their degree is established. The presence of barbs, delaminations and other defects is taken into account.
Welds
Before testing the racks, the joints of all elements of the system are inspected. They can be attached to each other with screws or welded. In these places, as a rule, the design is most susceptible to the negative influence of the load. Therefore, the quality of the welds is determined by special methods.
This can be an ultrasonic, acoustic, luminescent or chemical method. Each of the selected methods allows you to assess the condition of the joints. At the same time, the presence of sagging, inclusions of slag or incomplete penetration is excluded at the seams. There should be no cracks or undercuts at the joints.
The check also establishes the cleanliness of the welds. They should not have scale or pollution. Otherwise, the system will quickly collapse.
If the connections are classified as screw type, their screed is evaluated. Paired elements (nut and bolt) must be tightened tightly.
Test procedure
When checking the quality and strength of racks, in addition to visual inspection and assessment of the quality of joints, other methods are used. They are addressed only after a satisfactory external state of the structure. In this case, the shelving is tested for load.
A similar check is performed in two directions. In the first case, the constituent elements are subjected to vertical load, and in the second - horizontal. These are effective techniques that allow you to objectively assess the condition of shelving.
Vertical load is applied to the beams. It exceeds by 25% the maximum allowable weight limit that the object can support. Data is taken from the construction passport. During the study, the deflection indicators are measured. It should not exceed the line 1/200 of the length of the beam.
The horizontal load of the shelves is 50% of the maximum value. Perpendicular deviation should be minimal.
Verification Completion
After testing the shelves, the residual deformation is measured. Again, a visual inspection of the object is performed. Welds or screw joints are also re-inspected.
At the end of the audit, an act is drawn up. It provides all measurement parameters. The check also sets the level of risk. Most often used to assess the European system of standards. It suggests three levels of risk.
If the equipment is assigned to the green zone, it has minimal damage that does not affect the bearing quality of the structure. The amber zone includes racks that have minor damage. However, their operation is permitted. If the object is in the red zone, its use is dangerous and is strictly prohibited.
Verification Benefits
Today, shelving tests are carried out without fail by all warehouse organizations and industries that produce such equipment. This allows you to assess the condition of the object of study, as well as approximately calculate the life of it.
In metal beams, crossbeams and support poles, stress builds up over time. At the same time, surfaces are periodically subjected to mechanical damage. This does not improve the condition of the shelving. If you do not pay attention to the defects that occurred on time, you can not avoid the collapse of the structure. It is the check that allows you to determine the impossibility of operating the structure before the fatal consequences.
The verification process also takes into account the features of operation, maintenance of shelving by warehouse personnel. For example, leased warehouses need to be checked more often, because they, as a rule, are not operated in a gentle manner.
Having examined the procedure for testing racks, you can qualitatively assess the condition of the structure. This will protect the object from destruction, injury and death.