The Rack Group Company Brochure

Your complete
warehouse

pallet racking
solution

The UK’s leading
pallet racking

safety specialists

• INSPECTIONS
• PLANNED MAINTENANCE
• SPECIALIST EQUIPMENT
• PROTECTION
• TRAINING

The Rack Group Ltd are the UK’s leading We use our Rack Aid Management system
specialists in storage equipment safety. to offer complete compliance to the
Having been established for over 40 years, European Standard EN 15635 ‘Steel Static
our name is synonymous with creating Storage Systems - Application and
greater efficiencies and higher safety Maintenance of Storage Equipment’. This
standards in the material handling industry. promotes the continual development of our
products, services and systems - meaning
Our ethos is simple, we create innovative products and we remain completely focused on giving
services that are designed to save our customers time, the best solutions for warehouse safety and
money and disruption associated with their industrial functionality whilst always striving to provide
storage equipment inspection, maintenance and repair our customers with long-term cost savings.
costs. Over the years this has lead us to work with some
of the biggest names in both retail and manufacturing.

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Contents

An introduction to The Rack Group 2
Rack Aid Management System 4

Rack Aid in Action 5

Inspections 6-7

Planned Maintenance 8-9

Specialist Equipment 10

Front Upright
Reinforcement System (FURS) 11

Rack Armour Upright Protection 12 - 13

Rack Armour Barrier Range 14

End of Aisle Barriers 15
Bumper Barriers 16
Pedestrian Barriers 17

Rack Training 18 - 21

Rack Trader 22

Contact Us 23

Copyright © 2016 by The Rack Group Ltd. All rights reserved. This publication or any portion thereof may not be reproduced
in any manner whatsoever without the express written permission of the author and company.

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Rack Aid Management System

Rack Aid is the UK’s most effective system to reduce your racking repair bills.

Created to counteract the potential of spiralling costs of racking repair, Rack Aid means you can
benefit from The Rack Group’s experience and complete service to create a management system which
will reduce racking damage now and for many years in the future.

www.therackgroup.com Tel: +44 (0) 1226 784 488

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Rack Aid

in action:

1. Safety Inspections

The Rack Group offer a cost effective and
thorough pallet racking inspection service that
not only gives you an in-depth inspection
report to the EN 15635 standard, but also an
easy to understand document highlighting
damaged areas and a no obligation quote
to rectify it.

2. Planned Maintenance

Scheduled maintenance allows our team to
repair or replace damaged components
found during the safety inspection, which
helps to ensure your pallet racking is safe
and fit for purpose.

3. Specialist Equipment

Over the years we’ve designed numerous specialist
repair methods which have been proven to increase
the safety of your pallet racking and reduce the costs
and hassle of replacements.

4. Rack Protection

Rack Armour - our innovative racking protection
product range - has been developed to safeguard
your warehouse racking systems from damage.

5. Rack Training

We offer a range of pallet racking training courses
which have been created by industry experts to
provide your staff with the necessary skills and
knowledge, whatever their level.

5

Inspections

The Provision and Use of Work Equipment Regulations state that pallet
racking is work equipment and must therefore be checked annually by
a competent person.

6

Our pallet racking safety inspection service is very Did you know?
thorough and cost effective. You can be totally
confident that you will receive the right advice as our SEMA guidelines suggest you
experience and knowledge of the industry is second have an appointed person who can
to none - to the point where we have even been a inspect racking on a weekly/monthly
part of creating a National Vocational Qualification in basis. If this is something you need
Pallet Racking Inspections. in your business, then Rack Training

As we carry out an inspection we use a digital can deliver comprehensive
technology system which enables us to provide you inspection training courses
with a detailed report to EN 15635 standard. This is
an easy-to-understand document which highlights in a variety of formats to
any damaged areas using SEMA’s Green, Amber and suit you - see page 18.
Red system.

Following the report, we will provide a same-day
action plan of our suggested requirements along
with a no-obligation quote to carry out the work.
These will include the various repairs needed
along with any replacement parts that we would
recommend.

Our racking repairs have been proven to cut bills
for many companies that utilise warehouses - all
whilst improving safety in the workplace.

The Rack Group has provided Britvic’s
factory at Leeds with an excellent racking
inspection service for over 7 years. Not only have
they advised on repairs and remedial work, but we
have also received expert guidance on numerous
other issues regarding the huge amount of racking
we have on site. It really is an all-round service and

something The Rack Group should be
very proud of.

Kevin Simpson, HSE-Coordinator - Britvic

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The continual working partnership
between Asda-Walmart and The Rack Group

has proven to be an essential part of our
commitment to reducing maintenance and
repair costs while ensuring a safe working
environment for our staff. The combination
of regular safety inspections of our pallet
racking, the reduced cost of spare parts and
additional time-saving maintenance skills are

proving to be a winning combination.

The complete service provided by The Rack
Group is world class and takes away the worry

of health and safety issues - all whilst
delivering fantastic commercial results with

the cost of replacement equipment.

Andy Walker, ASDA-Walmart

8

Planned
Maintenance

The crucial stepping stone between our
pallet racking inspections and the
various repair services available is ‘step
two’ of the Rack Aid Management
System - Planned Maintenance.
This ensures that our customers can
be proactive when it comes to
pallet racking repairs.

Did you know?

Our repair and
maintenance package
has saved one customer

£1,000,000 in their
first year alone!

During the inspection process our team
will gather detailed information so we can
analyse our customers racking damage
trends. We will then work with you to plan
and prevent any repeat repairs - all of
which can save you significant amounts in
the long term.

This knowledge also enables us to hold
sufficient stock at all times for any
replacement parts needed, which then
means our maintenance team can carry
out any repairs quickly, efficiently and cost
effectively.

The diversity of services offered by The
Rack Group can help with planning any
other requirements you may have in future
- whether that may be with additional staff
training, replacement parts or ongoing
health and safety advice.

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Specialist I can’t compliment
Equipment your team enough for the work

Racking is extremely vulnerable to damage from they have done for us. It’s
material handling equipment - sometimes it can certainly made my life easier
take only a small accidental impact to render the
racking dangerous and not fit for purpose. That’s and your team are all a
why The Rack Group are constantly creating new pleasure to work with.
methods to stem the damage levels whilst
creating cost effective methods to repair any Ian Allen, Eddie Stobart
issues caused.

A typical example of these problems is with welded racking
frames as they will often need full frame replacements even
after minor damage. We have developed an innovative repair
method where we will either cut out the impaired section, or
re-strengthen it with our FURS. Either way, we can prolong the
life of your racking at a fraction of the cost of a replacement.

We are able to offer bespoke solutions to any particular
problem you may have. We understand that damage can often
be quite unique depending on the individual situation - that’s
why you can take great confidence from the years of experience
held within The Rack Group team. We will always be
able to give you a robust and cost-effective
solution, no matter what damage
has been caused.

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Front Upright
Reinforcement Section
(FURS)

Of all our specialist repair methods, our Front Upright
Reinforcement Section (FURS) is the one that offers
the biggest cost savings compared to replacement
parts.

We know that 90% of all racking damage occurs
within the lowest 600mm of the upright leg. But when
the leg becomes unsafe, the full upright is often
replaced - which can be very costly of course. Using
our specialist equipment, we can prop up your
existing racking, cut away the damage and then
insert our FURS. Made from reinforced steel, the
FURS creates an almost indestructible base to your
racking system and obviously saves on the need for a
full replacement part.

In most cases we can install our FURS without having
to offload a single pallet, meaning we can repair a
leg in roughly 20 minutes with minimal disruption to
your operations.

Torn Repair (High Level of Damage)

If your bracing is torn and badly damaged we can
fix it using our bespoke replacement product, to do
this we simply remove the old damaged bracing and
install our replacement which gives you the benefits
of a bolted bracing on your existing welded frame.
This process does NOT require a hot works permit as
we use specialist tooling and enclosed screens which
in turn eliminates disruption on your site.

Bent Repair (Small Level of Damage)

If you have bracing that is lightly damaged and bent
out of place, we can repair the damage and also
strengthen the bracing with our bespoke Redirack
wrap around product. This product is unique to
The Rack Group and enables us to repair damaged
bracing without offloading and replacing the whole
frame.

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Rack Armour
Upright Protection

Rack Armour, our racking upright protection
product, has been a global success for over a
decade. Its innovative design and functionality has
revolutionised racking protection and provides

a proven 80% reduction in damage levels.

• Made from ballistics grade plastic meaning
it is able to deflect impact in most cases.
• When a direct impact occurs and cannot be
deflected by the outer shell, the interior
foam absorbs the impact energy until it’s
diffused.
• Its tight fit ensures that Rack Armour can’t
be knocked off whilst pallets are retrieved.
• Hi-visibility colour clearly gives safe working
boundaries for MHE drivers.

The Rack Armour
Upright Protection

Range

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Fully Tested

Rack Armour has been rigorously tested
to meet and exceed European Standards.

The testing procedures include
replicating a forklift truck weighing 2 tons
travelling at 1.8 meters per second, which
simulates an impact to the racking with
a force of 21.6 kilo newtons (2.4 ton).

With Rack Armour fitted, the 3mm Did you know?
buckle is prevented after 8 hits in
exactly the same spot. With no Rack Armour is now over
protection in place, the upright a decade old! The very first
was damaged and buckled after
just one hit. guards we produced are
still being used to give

protection to
this day.

There are many Foam interior
benefits of using diffuses impact
Rack Armour
energy to
• It reduces racking damage by as much as 80% protect uprights
- saving you time, money and hassle.
Bright colour
• The ‘persistence of shape’ ensures a long and aids detection
effective lifetime service. for MHE drivers

• Quick and easy installation as no fixings are Fits all makes
required - can be fitted in seconds. and models of
pallet racking
• Fits all makes of pallet racking and is
transferable. HDPE tough
outer shell
• High visibility colour helps with
warehouse safety. deflects impacts
and shields
• Materials are non-toxic and
fully recyclable. upright from
damage
• Impervious to moisture, mould growth,
corrosion, acid, alkaline & most solvents.

• Can be used at temperatures down to
-40 degrees centigrade.

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Rack Armour Barrier Range

New to the Rack Armour family, our barrier Absorption
range is made from the same components
as the industry leading Rack Armour upright Rack Armour barriers use the
protector, giving it the same impact and same unique foam diffuser as in
absorption qualities on a larger scale. the upright protector, helping to
diffuse impact energy whilst
Benefits to our barriers include: a collision takes place.

Colour/Detection Strength

Standard metal systems are often a drab Rack Armour barriers flex and absorb
and dull metallic colour making them impacts which would render metal
almost unnoticeable to warehouse staff. systems useless. They have a unique
Rack Armour barriers are a striking high feature which enables the product to
visibility yellow, making them detectable to reform to its original shape after impact,
mechanical handling equipment giving you a product which can concede
operators, this in the first instance helps impacts all day every day and look like
stop impacts from occurring at all. it’s been untouched hours later.

Minimal Floor Damage No Painting

A standard metal barrier has no absorption Rack Armour barriers are made
qualities, this means that all the impact energy from a solid high visibility plastic,
from collisions transfer straight down to the this gives our barriers a clean and
expensive concrete floor. This in most cases tidy appearance even after years
leaves you with not only a damaged barrier that of service and numerous impacts.
needs replacing, but also a crumbled floor that Metal systems can often appear
needs relaying can be extremely expensive and tired and in need of repair, a level
time consuming work. A Rack Armour barrier of maintenance is required
flexes and absorbs impact energy through its including painting which takes
unique foam interior, eliminating any transferable time and money.
energy away from your floor, in turn saving you
thousands in repair costs.

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End of Aisle Barriers

When there is an impact on old-fashioned metal barriers it doesn’t take
long until they bend, break and begin to rip up the floor fixings. The
repainting required once they get damaged can also be painstaking.

The Rack Armour barriers are made from a flexible HDPE polymer meaning
it absorbs the impact and can take hit after hit without becoming dented
or damaged.

Single Rail Barrier

A perfect blend of strength, visibility and durability.
Available at either 320mm or 420mm high, it’s an
all-round solution as it can take multiple impacts whilst
reforming to its original shape.

Double Rail Barrier

This barrier has been designed with vision in mind, standing
at an elevated 620mm high. This gives your rack ends solid
protection whilst also being a highly visible indicator to
those operating MHE - meaning impacts are often avoided.

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Bumper Barriers

Double Bumper Barrier

Offering you complete warehouse protection by creating safe zones of
highly visible barrier systems. Standing at 600mm tall, this is the ideal
solution if you feel you need extra protection.

Floor Rail Bumper Barrier

Perfect for providing subtle protection within picking areas of
the warehouse. Frequent floor fixings mean it is strong and durable and is also
ideal for placing at the back of bays to prevent pallets being hit against walls or racking.

Single Bumper Barrier

The single bumper barrier is a low level barrier at 310mm tall,
which is given strength from its multiple legs anchored to the
ground. This barrier is our most popular design giving users the
right amount of visibility and strength whilst maximising space.

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Pedestrian Barriers

Rack Armour Pedestrian Barriers have been designed A
with both safety and segregation in mind. They are B
ideal for highlighting safe pedestrian areas and aisles C
and, as well as the standard high visibility yellow D
colour, are also available in a red and green colour to
locate fire equipment or first-aid areas.

• Available in any desired length.
• Choose from either two or three rails.
• Combinations of Single Pedestrian and Double
Bumper Barriers can be used where FLT impacts
are more likely to occur.
• The cylindrical barrier section increases flexibility
whilst providing a deflection element to keep
accidents away from vulnerable areas.
• All are compatible with the Rack Armour Gate
system which can be inserted within the vertical
posts of the barriers. The gate is also made of
ballistics grade polyethylene to ensure they can
resist FLT impacts as well as frequent use.

A Standard Pedestrian Barrier

The original standard Pedestrian Barrier is
available with either two or three rails.

B Single Bumper Pedestrian Barrier

Where there is a higher chance of collision,
the Single Rail, taken from the Bumper Barrier
range adds the extra deflection and strength
to increase the level of safety.

C Double Bumper Pedestrian Barrier

Where pedestrians and MHE will frequently
pass each other, there is no better protection
than the Double Pedestrian Barrier. Easy to
see and hard to breach, this is the ultimate in
warehouse protection and segregation.

D Warehouse Bollard

This stand alone protective unit within the
warehouse is a cost effective solution to
protect corners and structures with minimal
space intrusion.

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Rack Training

Rack Training is our specialist division providing improved skills training for
people looking to work in the industrial storage equipment industry.

Utilising the knowledge gained by our staff from years of industry knowledge, a series of training courses
have been created which conform fully to the European Standard for Storage Equipment as well as all
other relevant Health and Safety legislation. Courses are available for staff at all levels from the basics
of pallet racking through to the Person Responsible for Storage Equipment Safety (PRSES). We can also
offer what is currently the only OfQual approved National Vocational Qualification (NVQ) in 3 individual
qualifications including the installation, inspection and maintenance of pallet racking.

If any of the courses on offer don’t quite fit with your requirements, then we are more than happy to
develop a bespoke course and will work with you to ensure all necessary topics are covered.

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Pallet Racking Damage Inspection Training

Many companies are not aware that a ‘Person Responsible for
Storage Equipment Safety’ is required for every site which contains
pallet racking and storage equipment.

If you are one of these individuals then our Pallet Racking Damage
Inspection Course is ideal for you.

It covers 7 detailed modules highlighting all the essential aspects
of pallet racking safety. This includes how to conduct an
inspection, common hazards and the relevant legal requirements.

Lasting two days, candidates will be assessed on both theoretical
knowledge and a practical inspection of pallet racking.

Pallet Racking Courses National Vocational Qualifications
(NVQ’S)
Pallet Racking Damage Awareness
Acquiring the skills and knowledge on-the-job
As well as being an ideal refresher course for those
who have carried out our damage inspection Rack Training offer three NVQ’s in pallet racking.
training, this course is suitable for warehouse These specialise in Maintenance, Installation and
supervisors and team leaders who hold Inspections; and have been designed to utilise
responsibility within the warehouse environment. practical assessment to ensure that on-the-job
requirements are being carried out effectively.
Pallet Racking Maintenance Training
Every member of The Rack Group’s site-based
Aimed at employees who need to perform team is enrolled onto this NVQ
essential repair and maintenance tasks on pallet to ensure our professional
racking systems, the skills training ranges from standards are met. It is a
replacing a beam to full frame and installations. great way of rewarding
The course duration can vary between 1 and 4 days candidates with
depending on the complexity of learning required. recognition for the
important skills in this
Pallet Racking Safety Awareness Training industry.

This course is great for all new employees with
little experience who will be expected to work
around pallet racking on a daily basis.

E-Learning Training Courses

The e-learning courses from Rack Training take away the pressure
of the classroom environment. Modules can be completed in any
location and the user can go through it all at their own pace. All courses
are taken online so candidates can complete the training wherever they have

an internet connection - at home, at work or even on the bus!

Throughout the course, quizzes and tasks are set; where there is a minimum pass
rate in order to achieve the certificate. However, users can always go back to take in

any information they missed and retake any particular section.

Managers are also able to login so they can monitor employee activity and success.

Current Courses Available: • Pallet Racking Safety Awareness Training
Courses Coming Soon: • PRRS - Person Responsible for Racking Safety
• Pallet Racking Damage Awareness Training

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We approached Rack Training
looking for a bespoke training course in
fallen pallet recover. After speaking with Tim
Smith (Training Manager) he said that he
would be able to develop a bespoke training
course purely to suit our exact needs and
requirements. The training course suited us
down to the ground, and Tim brought with
him a wealth of experience and knowledge
which was delivered clearly greeted with
interest. We look forward to welcoming Tim
back for more training in the near future, and
would recommend Rack Training Limited to

any company needing training in the
warehousing and pallet racking industry.

Shaun Davies, DHL

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IOSH Health and Safety Training Pallet Racking Inspection Kit

As well as our choice of pallet racking training Rack Training want to ensure that inspecting
courses, Rack Training can also provide a range of pallet racking is carried out correctly - and can
safety training, which is available in different formats. give you all the tools you need to do this.

IOSH Managing Safely The Kit Includes:
• An easy to carry, durable bag
A four day course designed for managers and • Quality branded tape measure
supervisors of any organisation who hold a • Spirit level
responsibility for health and safety of their staff or • Steel rule
team. • Straight edge
• String line
IOSH Working Safely • Torch
• Tapered wedge
A one day course to meet Government guidelines for • Guidance information
introductory health and safety training for people at • Sample reporting books and hazard
any level in any sector. identification labels

All of our courses provide interactive sessions which
are used to assess the theoretical and practical
knowledge. The trainers all have site experience so
know how to make the courses more interesting and
relevant to the real-world working environment.

CIEH Qualifications

It’s vital that you make sure your staff members are
ready in case they are ever needed in an emergency.
Our First Aid training is delivered by experts who
understand your specific working roles and the
warehouse environment, making the learning
experience more enjoyable and relevant.

Current Courses Available:

• Three day first aid training

• One day first aid training

• A first aid refresher course

• Manual Handling
(one day or half day courses available)

• Risk Assessments
(one day courses available)

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We are now one of the Rack Trader
largest stockists of used
pallet racking throughout With low budgets to work with, companies are always
the UK, so we can offer looking for ways to find cost effective racking for their
extremely competitive warehouses. That’s why we created Rack Trader - our
prices for your surplus division for the buying and selling of new and used
and used racking. racking. Rack Trader dedicates itself to finding quality,
affordable pallet racking which is sourced through our
Why buy new?.. Rack extensive research and knowledge of the market.
Trader holds a substantial
supply of second hand Our service also includes racking installation, decommissioning and
racking and racking alteration works. We’ve been in the business long enough to know
components for minor that warehouse operations can change from time to time, so we are
repairs and extensions, perfectly placed to help customers with altering existing storage
giving you a quick and easy equipment to accommodate new products or requirements.
way to buy the items you
require at affordable prices. All installation and decommissioning work is carried out in line with
current health and safety legislation incorporating risk and method
We also hold a large statements. The Rack Group are able to give competitive quotes on
stock of bolted Redirack unwanted racking and we also ensure all left over materials are 100%
compatible racking at recycled to meet our stringent environmental policy.
fantastic prices. This could
also save you money on
any future repairs.

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For more information please contact us
during our office opening hours;

8am - 5.30pm Monday to Thursday.
8am - 5.00pm Friday

Tel: +44 (0) 1226 784 488
Fax: +44 (0) 1226 784 499
Email: [email protected]
www.therackgroup.com

The Rack Group Ltd, Unit 3, Shawfield Road,
Carlton Industrial Estate, Barnsley, S71 3HS,

United Kingdom

The UK’s leading pallet racking
safety specialists.

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A thousand less
things to worry about

With over 40 years experience, you can trust The Rack Group to
look after all your racking requirements from inspections to training.
Don’t let racking give you a headache - leave it to the professionals.

3 Racking inspections 3 Racking protection 3 Inspection training
3 Racking repairs 3 Racking alterations 3 Maintenance training
3 Racking solutions 3 Racking decommissioning 3 NVQ qualifications

www.therackgroup.com [email protected] Tel: +44 (0) 1226 784 488