stacking and storage standard functional area: e · pdf filedocument template 32-4 revision 7...

Document Template 32-4 Revision 7

Stacking and Storage Standard

Title: Stacking and Storage Standard

Document Identifier: 240-93411424

Alternative Reference Number:

N/A

Area of Applicability: Eskom Holdings SOC Ltd

Functional Area: E

Revision: 1

Total Pages: 27

Next Review Date: August 2020

Disclosure Classification:

Controlled Disclosure

Stacking and Storage Standard Unique Identifier: 240-93411424

Revision: 1

Page: 2 of 27

CONTROLLED DISCLOSURE

When downloaded from the document management system, this document is uncontrolled, and the responsibility rests with the user to ensure that it is in line with the authorised version on the system.

No part of this document may be reproduced without the express consent of the copyright holder, Eskom Holdings SOC Ltd, Reg. No. 2002/015527/30.

Content

Page

1. Introduction .................................................................................................................................................. 3

2. Supporting Clauses ..................................................................................................................................... 3

2.1 Scope ................................................................................................................................................. 3

2.1.1 Purpose .................................................................................................................................. 3

2.1.2 Applicability ............................................................................................................................ 3

2.1.3 Effective date ......................................................................................................................... 3

2.2 Normative/informative references ...................................................................................................... 3

2.2.1 Normative ............................................................................................................................... 3

2.2.2 Informative ............................................................................................................................. 4

2.3 Definitions ........................................................................................................................................... 4

2.4 Abbreviations ...................................................................................................................................... 5

2.5 Roles and responsibilities .................................................................................................................. 5

2.6 Process for monitoring ....................................................................................................................... 5

2.7 Related/supporting documents .......................................................................................................... 5

3. Stacking and Storage Standard .................................................................................................................. 6

3.1 General requirements......................................................................................................................... 6

3.2 A safe work system ............................................................................................................................ 7

3.3 Stacking/storage principles ................................................................................................................ 8

3.4 Size and shape of stacks ................................................................................................................... 8

3.5 Stability and bonding of stacks ........................................................................................................... 9

3.6 Stacking different types of goods ..................................................................................................... 10

3.7 Waste material ................................................................................................................................. 14

3.8 Rules for destacking ......................................................................................................................... 14

3.9 Storage inspections .......................................................................................................................... 15

3.10 Stock holding structures and automated storage standard .............................................................. 15

3.11 Rules for safe racking....................................................................................................................... 17

3.12 Automated systems (carousels, automated pickers, automated high-rising shelves) ..................... 18

3.13 Material handling equipment ............................................................................................................ 18

3.14 Safe storage and material handling principles ................................................................................. 19

3.15 Manual handling ............................................................................................................................... 21

3.16 Rules for safe stacking ..................................................................................................................... 22

3.17 Safe stock movement ....................................................................................................................... 23

3.18 Segregation of stock......................................................................................................................... 23

3.19 Shelf life ............................................................................................................................................ 24

3.20 Training of employees ...................................................................................................................... 25

4. Acceptance ................................................................................................................................................ 25

5. Revisions ................................................................................................................................................... 25

6. Development Team ................................................................................................................................... 26

7. Acknowledgements ................................................................................................................................... 26

APPENDIX A: INSPECTION FREQUENCIES ................................................................................................ 27


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1. Introduction

Annually, accidents occur while goods are being stacked or destacked and put into, or taken out of, storage. Many of these accidents are serious and have led to fatalities.

This standard is designed to assist the organisation to develop safe and effective methods for stacking and storage in line with legislative requirements. Eskom has a duty to create and maintain, as far as reasonably practicable, a working environment that is safe and without risks to the health and safety of the employees. This responsibility is reinforced in Eskom’s Safety, Health, Environmental, and Quality (SHEQ) Policy, along with other legislative obligations.

2. Supporting Clauses

2.1 Scope

This standard defines the framework to be adhered to with regard to stacking and storage operations, including the dismantling/destacking of stacked goods, materials, substances, or equipment, to ensure that these activities are carried out safely in accordance with legislative requirements.

2.1.1 Purpose

The purpose of this standard is to outline the process to manage the risks associated with stacking, storage, and the dismantling/destacking of stacked goods, materials, substances, or equipment in and around warehouses as well as to ensure that a common approach is adopted throughout the organisation to prevent stacking and storage incidents.

2.1.2 Applicability

This document shall apply throughout Eskom Holdings SOC Limited, including its divisions, subsidiaries, contractors, and where Eskom has a controlling interest.

2.1.3 Effective date

The implementation date of this procedure is August 2015.

2.2 Normative/informative references

Parties using this document shall apply the most recent edition of the documents listed in the following paragraphs.

2.2.1 Normative

[1] ISO 9001 Quality Management Systems

[2] 240-62582234 OHS Roles and Responsibilities and Statutory Appointment

[3] Occupational Health and Safety Act (Act 85 of 1993), including General Safety Regulations and Construction Regulations, 2014


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[4] 32-727 Safety, Health, Environment, and Quality (SHEQ) Policy

2.2.2 Informative

[1] SANS 10263-2 The Warehousing of Dangerous Goods

2.3 Definitions

Definition Description

Batten A long flat strip of squared timber or metal used to hold something in or as a fastening against a wall.

Bund A wall of earth or brick that will contain oil, silt, or other similar liquids in order to contain them in the event of a spillage. This area must be able to contain at least 110% of the stored material.

Column Single articles placed one above the other.

Dunnage Any scrap material used to stack material, that is, sleepers.

Employer Means any person who employs or provides work to any person and remunerates that person or expressly or tactically undertakes to remunerate him/her.

FIFO Shelf-life items that have expiry dates shall be issued on the principle of first in, first out.

Lean-to pyramid Or stepped on one side and vertical on the other three sides.

Periphery The outer limits or edge of an area or object.

Pyramid A stack in which the plan area is reduced in every succeeding tier or at least every fifth tier.

Risk assessment Means a process of determining any risk associated with any hazard in order to identify the steps needed to be taken to mitigate, remove, reduce, or control such hazard. A risk assessment is typically a careful examination of what could cause harm to people as a result of a work activity, and it allows you to take the necessary precautions to prevent the harm occurring.

Stepped Stacks with two or more adjacent tiers of the same area and each succeeding group of tiers of a smaller area than the group on which it is set.

Square Any stack, other than a column, with all sides vertical.

Triangular Stacks in pyramid or stepped form on two opposite sides, the other two sides being vertical.


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2.4 Abbreviations

Abbreviation Description

A&F Assurance and Forensic

FIFO First in, first out

kg Kilogram

l Litre

MSDS Material safety data sheet

OEM Original equipment manufacturer

OHS Occupational health and safety

PCM Process control manual

PPE Personal protective equipment

SHEQ Safety, health, environmental, and quality

STOP Stock transport purchase order

t Ton

UV Ultraviolet

2.5 Roles and responsibilities

Line management and contractors shall take all reasonably practicable steps to prevent incidents emanating from stacking and storing activities.

2.6 Process for monitoring

Compliance with the requirements of this standard must be audited by the operating/business unit at least annually as part of an internal review process.

All records in terms of paragraph 3 will be audited by Assurance and Forensic Department (A&F) or any person delegated by A&F to carry out the audit and at a frequency determined by A&F.

2.7 Related/supporting documents

[1] 240-83290895 Stacking and Storage 28(a) 2014 Construction Regulations

[2] 240-98741777 Warehouse Racking Inspection Report

[3] 240-75521456 Phase Conductor for Eskom Overhead Lines

[4] 32-1271 MV Cables

[5] 32-1272 LV Cables

[6] 32-245 Waste Management Procedure

[7] 240-62196227 Standard on Life Saving Rules


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3. Stacking and Storage Standard

3.1 General requirements

3.1.1 Stacking operations shall be undertaken by, or under the supervision of, a person with specific knowledge and experience of this type of work.

3.1.2 All new racking specifications shall be reviewed by an appointed project manager.

3.1.3 The appointed project manager must ensure that commercially manufactured stacking and storage infrastructure are installed, used and maintained in accordance with the manufacture’s specifications.

3.1.4 The appointed project manager must ensure that all stacking and storage infrastructure used outdoors, are designed, constructed and maintained to support loads placed on them by wind and other environmental conditions.

3.1.5 Stacking and storage at construction sites shall be carried out under the supervision of a competent person who shall be appointed in writing in terms of the Construction Regulations.

3.1.6 Risk assessment, specific to the stacking activities, shall be completed for the work to be conducted.

3.1.7 Persons carrying out stacking and storage activities, including dismantling/destacking of stacked equipment, shall be appropriately trained.

3.1.8 Appropriate personal protective equipment (PPE) shall be issued to persons carrying out stacking, storage, and dismantling/destacking of stacked material/equipment, and suitable training must be provided on the use, care, and maintenance of the PPE. The type of PPE to be worn shall be dependent on the area where the work is to be carried out and will be informed by the risk assessment.

3.1.9 A safe work procedure/task analysis and work instructions, which are approved by a competent person, shall be in place and readily available for use.

3.1.10 The stacking of articles shall be as per General Safety Regulation (8) of the Occupational Health and Safety Act and Regulations (85 of 1993).

3.1.11 Procedures shall establish when inspections need to be carried out on the equipment used for stacking; storage and dismantling/destacking of stacked material/equipment and regular inspections shall be undertaken in accordance with such procedures. These inspections may be initiated by either the SAP PM system (Generation Division) or the manual system (Distribution Division) in accordance with the OHS Act. These inspection records shall be filed for auditing purposes.


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3.1.12 Stacking shall be done on level floors that are capable of supporting the weight, which is predetermined during the construction phase of storage areas.

3.1.13 The stability of stacks shall not be endangered by vehicles or other machinery or persons moving past them.

3.1.14 Sufficient and suitable lighting, whether natural or artificial, must be provided in every part of a stacking undertaking, including outside yard and storage areas where workers are employed or pass in accordance with the OHS Act.

3.1.15 Storage areas shall be kept neat and under control.

3.1.16 Bulk storage of combustibles should be positioned so as to minimise the risk of fire occurring within the stack or spreading from or to adjacent areas in case of fire emergency.

3.1.17 In general, stacks should be at least 2 m clear of perimeter boundaries and be divided by cleared gangways of at least 1 m.

3.1.18 Stacks that are in danger of collapsing should be dismantled immediately in a safe manner.

3.1.19 No persons shall be allowed to climb onto or from a stack. If/when the necessity arises (verification of poles in pole stacks), the Life Saving Rules Standard (240-62196227) shall be adhered to.

3.1.20 It is advised that free-standing or stacked U-frames not be used for storage, since they are inherently unstable, and stacks may collapse. All U-frames are viewed as high risk and must be converted to cradles.

3.1.21 All storage systems should comply with all the relevant regulations.

3.2 A safe work system

3.2.1 Reasonable steps shall be taken to ensure that all goods, materials, substances, and equipment in warehouses are so stacked, stored, secured, and kept that they do not constitute a danger to persons in the vicinity during the course of daily operations.

3.2.2 Such steps shall be taken to ensure that these items cannot, whether of their own accord or by virtue of any external force (intentionally applied or otherwise), so flow, move, roll, or collapse as to constitute a danger to persons in the vicinity.

3.2.3 All workers responsible for stacking, storing, securing, or keeping of any goods, materials, substances, or equipment shall attend training on safe methods of conducting stacking, storage, and dismantling/destacking of stacked goods, materials, substances, and equipment.


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3.2.4 A safe work system relies on:

• adequate training and instruction for the entire workforce; • comprehensive planning, incorporating the views and opinions of those who will

operate the systems, when required; • adequate supervision and control; and • adequate information to enable the workforce to carry out their tasks in a safe and

healthy manner.

3.3 Stacking/storage principles

3.3.1 Vendor stacking requirements shall be applied.

3.3.2 Overflow shall be prevented by binning in a larger storage area, where possible.

3.3.3 Demarcations shall be clear.

3.3.4 Stored materials can be:

• free-standing, that is, material is placed or stacked on the ground without any fixed supports or racks or stored on the floor on bearers; or

• supported, that is, material is restrained or supported by racks or other permanent or semi-permanent storage equipment (including a frame or stillage).

3.3.5 The choice of storage system will depend on many factors, including:

• type and stability of stock; • handling system to be used; • anticipated stock quantities; • frequency of movements; • picking requirements of the user; and • recommended storage procedures from the OEM.

3.4 Size and shape of stacks

3.4.1 The size and shape of a stack depend on the storage space available and on the size, shape, bulk, weight, rigidity, or fragility of the articles to be stored.

3.4.2 The following are the most common forms of stacking:

• Column • Square • Pyramid • Stepped • Triangular • Lean-to pyramid


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3.4.3 It is important to remember that the aggregated weight of the stack is borne by the lowest tier, which should be strong enough to bear the superimposed load.

3.4.4 Untidy stacks offend the eye and are rarely safe by construction, since it is usually bad methods of construction that cause untidiness.

3.4.5 If a stack appears to be unstable, it should be broken down immediately and rebuilt properly.

3.5 Stability and bonding of stacks

3.5.1 Stable construction of stacks is entirely dependent on the following factors:

• Safe relation of the height to the dimension of the base • Sound interlocking of goods • Contents of the sacks or cartons • Compact construction and avoidance of transfer stress in any dunnage used for

artificial bonding • Shape of articles • Determination of the aggregate weight to be borne by the components in the lowest

tier of the stack • Good placing of every component forming part of the stack, with special care taken to

avoid overhang on any side or end of a stack intended to be vertical

3.5.2 Resistance to collapse, strength, and stability of stacks should be maintained by bonding, stepping, tying, or other means.

3.5.3 The ratio of height-to-base dimensions of large stacks should be correctly proportioned so that failure of part or whole of the stack does not occur.

3.5.4 The height-to-base ratio of an unsupported stack should not exceed 3:1.

3.5.5 As most stacks are erected by visual alignment, a slight error in calculation near the base can easily result in a barely noticeable overhang, with a resultant loss of stability. The height should not exceed three times the shortest base.

3.5.6 The shape of goods or packages to be stacked will have a great bearing on the type of bonding used.

3.5.7 When one dimension is appreciably greater than the other two, it will be possible to use natural bonding, that is, to secure stability by interlocking the articles themselves. In other circumstances, it will be necessary to introduce other materials (for example, plastic sheets, battens, piling sticks, etc.) to prevent movement of the articles stacked; this is known as artificial bonding.


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3.5.8 Outdoor stacks are affected by weather conditions such as rain, wind, frost, and sun. These conditions can greatly influence the stability of stacks over time and should be taken into consideration.

3.5.9 Materials that can be dislodged or blown off the top of a stack under windy conditions should be tied down or otherwise restrained.

3.5.10 If tarpaulins are used to secure or protect the stacks, they should be fastened to independent anchorage, not to the stack itself.

3.6 Stacking different types of goods

3.6.1 Bagged goods

• The first tier should be so arranged that the bags can be spread flat, and the same should be done in succeeding tiers. Interlocking should be used, if possible.

• Where possible, the mouths (opening) of the bags should be on the inside of the stacks.

• Bagged material of different sizes and shapes should not be stacked on top of one another, unless proper precautions are taken to prevent movement by settling or vibration.

• Pallets with spacers or some form of horizontal bonding should be used if there is a risk of such movement or if it is intended or necessary to stack high.

• Special precautions should be taken with synthetic bags or sacks, which have a tendency to slip when new.

3.6.2 Chemicals

• Chemicals shall be stored inside a controlled environment with proper ventilation and in a bund area with adequate capacity to contain spillage.

• Material safety data sheets (MSDSs) shall be filed and displayed with each product.

• Handling and transporting regulations shall be adhered to.

• Clear demarcation shall be applied.

3.6.3 Cartons

• Careful consideration should be given to the weight of stacks of cartons.

• Dampness will reduce the strength of cartons, and a damp flow may well lead to damage of the lowest tier and ultimate collapse of the stack.

• Interlocking (for example, the bricklaying method) can be used in stacking cartons.

• Adhere to the pictorial markings on the cartons, when available.


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3.6.4 Bales

• Bales should be stacked with care to ensure their stability.

• Attention should be paid to possible vibration, and if possible, stacks should lean into their centre.

• Extra care should be taken with synthetic bales, which have a tendency to slip when new.

3.6.5 Wooden crates

• As most crates are reinforced with external battens, care should be taken to see that the battens bear the weight, not the crate.

• Adhere to the pictorial markings on the crates, when available.

• Outdoor stacking of crates is affected by weather conditions such as rain, wind, frost, and sun. These conditions can greatly influence the stability of stacks over time and should be taken into consideration.

3.6.6 Coiled wire

• It may be stacked horizontally or vertically.

• Wedges or other supports must be used to prevent the stack from spreading/rolling.

3.6.7 Glass bottles and jars

• Small quantities can be laid on their sides on top of one another, using wedges, where necessary.

• Otherwise, they should be stacked in cases, cartons, or racks designed to hold them.

• If pallets are used, spaces or some form of horizontal bonding should be incorporated.

• The overall weight of the stacks should not be borne by the glass itself.

3.6.8 Drums, casks, and cylinders

• The storage of cylinders shall be according to SANS 10263-2 (The Warehousing of Dangerous Goods).

• Cylinders shall be individually stored upright and chained on pallets.

• Cylinders are to be issued on an exchange basis (an empty bottle for a full bottle).

• The valves of gas cylinders under pressure must always be protected with a valve protector.

• Power-operated clamps on forklift trucks enable cylindrical objects such as cable drums or pipes to be stacked on end, allowing greater economy of space and greater stability.

• Oil drums shall be stored in a controlled environment with proper ventilation and in a bund area with adequate capacity to contain spillage.


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• When there is no racking or pallets available to accommodate 210 litre oil drums, these drums should be stored upside down to ensure that leaks can be easily detected as well as to prevent ingress of moisture.

• If 210 litre oil drums are stored on their sides, then both filling caps shall be fastened to the drums.

• MSDSs shall be filed and displayed with each product.



3.6.9 Sheet materials

• Sheet materials may be stacked flat or on edge. Sharp edges should be protected to prevent injury to workers and passers-by.

• The supports used in edge-on stacking must be of adequate strength to bear the side thrust of the vertical sheets.

• Owing to the weight of metal in bulk, care should be taken not to overload racks and the floor.

• All “self-built shelving” at all Eskom sites must be inspected/rated and certified by the Mechanical Engineering Department.

• Weight capacity must be clearly displayed.

• Risk assessments shall be performed at regular intervals.

• If any “self-built shelving” is found to not be fit for purpose, it should to be replaced with the correct type of shelving according to the requirements of this standard.

3.6.10 Steel tubes, bars, and joint sections

• Suitable racks should be provided for steel tubes, bars, joint sections, and similar materials.

• Large-diameter tubes or pipes can be stacked on their sides similar to drums.

• Wedges, chocks, stakes, or other means should be used to restrain the bottom tier of round objects that are stacked or tiered to prevent the stack from collapsing by rolling or moving.

• Where successive tiers are not nested by resting on battens, planks, or other flat surfaces, they should be restrained from moving by wedges secured to the battens or planks.

• Where the collapse of a stack or tiers of round objects could cause damage or injury when the material is removed, removal should always start from the top of the stack or from the top tier first.

• Long, narrow material is most stable when laid on its side and safest when stored horizontally in storage racks.


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• Horizontal storage and handling systems should be used in preference to vertical systems.

• Free-standing storage should be avoided, wherever possible.

• Bundling or packaging of stock can reduce sagging and make stock handling easier and safer. Bundles can be stacked and handled safely within a properly designed storage system.

• All “self-built shelving” must be inspected/rated and certified. Weight capacity must be displayed clearly.

• Risk assessments shall be conducted.

• If the “self-built shelving” is found to not be fit for purpose, it should to be replaced with the correct type of shelving according to the requirements of this standard.

3.6.11 Paint

• Paint shall be stored inside a controlled environment with proper ventilation and in a bund area with adequate capacity to contain spillage.

• MSDSs shall be filed and displayed with each product.


• All electrical equipment and lighting shall be flameproof.

• Fire officials shall supply compliance certificates for storage areas.


3.6.12 Idlers and pulleys

• Idlers should be stored in a pyramid shape contained by a flat bar.

• One pyramid should not be stacked on top of another.

• Adhere to OEM/supplier storage instructions.

3.6.13 Transformers

• Transformers shall not be stacked.

• All transformers, filled with oil, shall be stored in a bund area to prevent contamination in the event of a leak.

3.6.14 Cable drums

• Cable drums shall only be lifted using a bar through the centre of the drum.

• Cable drums shall not be stored flat and must be wedged.

• Cable drums may be stacked according to OEM/supplier stacking and/or storage recommendations.


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• All cable ends shall be capped, new or used.

• Special cable shall be stored according to OEM/supplier specifications.

• Cable drums shall comply with the supporting documentation as mentioned in point 2.7.

3.7 Waste material

Waste material shall be stacked, stored, and removed from sites according to the Waste Management Procedure 32-245.

3.8 Rules for destacking

3.8.1 Before destacking commences, a risk assessment shall be carried out.

3.8.2 Articles should be removed from the stack from the top-most tiers or part of those tiers of the stack.

3.8.3 The work should be done outward from the centre, reducing the periphery last, so that there is a barricade to prevent people falling off the stack.

3.8.4 One person only should be responsible for the manner in which the stack is reduced.

3.8.5 If the person in charge of the destacking had no part in erecting the stack, he/she should ascertain its construction before work begins.

3.8.6 When a large stack has been given a natural fence by building the periphery higher than the centre, this fence should be maintained during destacking.

3.8.7 If tubular or other fencing has been built in or around the stack, it should be dismantled and adjusted as the height is decreased.

3.8.8 As there is a high tripping hazard in the working area of a stack, tidiness and systematic work methods are essential.

3.8.9 Care should be taken to ensure that people working on stacks are clear of overhead travelling cranes at all times.

3.8.10 Proper signalling arrangements should be made.


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3.9 Storage inspections

3.9.1 All materials held in storage should be inspected to determine whether they are susceptible to damage, heating, deterioration, swelling, shrinking, corrosion, or attack by insects or rodents.

3.9.2 The frequency of inspection will depend on the type and method of storage.

3.9.3 Where these conditions are evident and could cause loss of stability, collapse, fire, or any other harmful effect, action should be taken to eliminate the hazard.

3.9.4 Incoming goods should be carefully inspected for damage of any kind before being placed in storage.

3.9.5 Racks, shelving, fixtures, and other equipment used for storing, loading, and unloading materials should be regularly inspected for damage and other defects that might cause loss of strength or result in damage or injury.

3.9.6 Any damaged or defective equipment should be taken out of service until repaired.

3.9.7 Electrical equipment and fittings should also be inspected and tested regularly.

3.9.8 Fire doors should be kept closed at all times, unless required to be opened for the movement of goods.

3.9.9 Any repairs, maintenance, or alteration work carried out in storage areas should be closely supervised to ensure the safety of workers and other people on the premises.

3.9.10 Use of equipment likely to give rise to a fire hazard should be closely monitored, and the use of a hot work permit system is recommended.

3.10 Stock holding structures and automated storage standard

Within Eskom storage environments, the following shelving/racking is most commonly used:

• Pigeonhole shelving with a load capacity of 120 kg per beam level

• Medium bulk shelving with a load capacity of 2 ton per beam level

• Heavy-duty bulk shelving with a load capacity of 3 ton per beam level

• Storage bins suitable for the size and type of material shall be provided for each item.

• Weight capacity must be clearly displayed at both ends.

• Risk assessments shall be conducted.


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• All “self-built shelving” at all Eskom sites must be inspected/rated and certified by the Mechanical Engineering Department.

• Weight capacity must be clearly displayed.

• If the “self-built shelving” is found to not be fit for purpose, it should be replaced with the correct type of shelving according to the standard and requirements.

3.10.1 Cantilever

• Racking consists of vertical struts and horizontal arms that hold the stored material.

• It is the least labour-intensive of the various types.

• It gives the greatest storage density and is the easiest to manage.

• It is considered to be the safest available to store tubes, pipes, etc.

3.10.2 Toast racking (for steel plates)

• Racking consists of substantial uprights (supported by a frame), with bundles of material being stacked between them.

• The uprights should restrain movement of the material and prevent it from toppling into gangways and work areas.

• The top of an upright should always be higher than the stack. Weight capacity must be clearly displayed.

3.10.3 A-frame racks

• These consist of an A-shaped upright frame fitted with arms similar to a cantilever rack.

• Materials are stored either horizontally across the arms or upright between the arms, when they are known as leaning racks.

• For horizontal storage, they can be designed to be loaded and unloaded by overhead cranes.

• When used as leaning racks, they should be equipped with base restraints (such as a lip or raised edge) and movable restraints (such as chains or bars) to prevent products from sliding or falling out of the rack.

3.10.4 Cradles

• U-frames can be made safer by modification to form “cradles”. Two U-frames are connected together by fixed cross-members to form a portable cradle with four feet.

3.10.5 Pallets

• Pallets used on high-rising shelving must be equipped with stopper blocks to ensure that they do not topple over the edges.


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• Material shall be secured to the pallets with straps and buckles, where applicable, if used on high-rising shelves.

• Consider the correct strength, size, number of entries, and manufacturing material for the required need.

• Loads should be uniformly distributed across the rack and stored so that heaviest materials are stored lower on the rack than lighter materials.

3.11 Rules for safe racking

3.11.1 Racking systems should adhere to the following:

• Be fit for purpose, that is, designed/sized to accommodate and safely support the maximum anticipated loading and be safe for their intended use.

• Be properly and safely installed by trained and competent personnel, for example:

� a suitable structural survey should be carried out to ensure that the proposed racking system (and anticipated stored material) can be safely accommodated;

� double-sided runs should be connected and spaced using suitable run spacers;

� end uprights may need to be strengthened, if alongside a gangway or pedestrian route, to contain any possible collapse of the racking system;

� when adjustable pallet racking is installed, beam connector locks should always be securely fixed at the ends of each beam to prevent accidental displacement of the beam, for example, by forklifts; and

� highly visible colours for key components of the racking, for example, horizontal beams or column guards, will help forklift drivers position the forks correctly and may help avoid damage.

• Be erected on sound, level flooring capable of withstanding the point loading at each base plate.

• Incorporate safe means of access for all foreseeable access requirements, for example, attachment of lifting accessories, stocktaking, etc.

• Be securely fixed to the floor and suitably protected against impact damage (the fitting of suitable column guards may help to protect uprights against impact damage from moving mechanical equipment).

• Be clearly marked with a notice stating their safe working load (SWL) or rated capacity, together with any necessary specified load configurations at both ends.

• Be properly interfaced with associated handling equipment; for example, aisles should be wide enough to ensure that mechanical handling equipment can be easily and safely manoeuvred and without risk of damage to racking; overhead clearances should be sufficient to permit the safe operation of cranes and lifting equipment.

• Be properly used, that is:

� in accordance with the manufacturer’s guidance;

� within their maximum SWL/rated capacity; and

� loads should be uniformly distributed across the rack and stored so that heaviest materials are stored lower on the rack than lighter materials.


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• Not be altered, nor components removed, without confirmation from the manufacturer that it is safe to do so.

• Only be used by fully trained/competent employees. • Be regularly inspected; it is recommended that records of inspection and follow-up

action should be retained. • Be maintained in an efficient state and in good repair; damaged components should

be repaired/replaced promptly.

3.12 Automated systems (carousels, automated pickers, automated high-rising shelves)

Where automated, computer, or remote controls are used for racking, selection of materials, or other stores functions, care should be taken that employees or other people in the area are not exposed to risk of injury through the operation of equipment.

• Automated storage equipment is designed for machine access, which can create hazardous areas between moving equipment and fixed installations.

• Only authorised employees are allowed to operate in these areas.

• Automated equipment should be isolated, or manual control applied, before attempting to rectify faults, particularly if parts of the equipment are extended.

• A means of access to, or egress from, extended equipment must be provided to eliminate the need to escape through any racking system installed.

• Controls should be such that, when switched from the disconnected “off” mode back to automatic, the previous cycle is unable to continue until a reset control has been operated.

• Access to racks from any side other than the operating side should be prevented, unless complete safety is assured.

• Conveyors and elevators should be properly guarded and be capable of being isolated from automatic control.

• Compliancy certificates are to be issued with the installation of a fixed automated lifting system before operation.

3.13 Material handling equipment

• Material handling equipment shall be selected, operated, and maintained to facilitate proper handling of goods stored and to limit risk of injury to workers or damage to goods and the environment.

• Equipment such as trolleys, hand trucks, pallet trucks, chain blocks, and slings used for moving and handling materials should be kept in a safe and serviceable condition.

• Equipment shall be tested according to any prescribed legislative requirements. All testing certificates shall be obtained and retained from the relevant testers.

• Equipment should be free of cracks or other defects that could cause failure of the equipment or injury to employees using it.

• Such equipment should be used only for the purpose for which it was designed.


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• Mechanical equipment such as cranes, hoist, scoops, stackers, forklifts, tele-loggers and ladders used in stacking, moving or loading materials should be kept in a safe and serviceable condition, and should be regularly inspected and maintained according to a Statutory Maintenance Schedule, based on engine-hour or motor-hour use is recommended. These inspections may be initiated by either the SAP PM system (Gx) or the manual system (Dx) in accordance with the OHS Act.

• It is the responsibility of the appointed maintenance departments (mechanical and electrical) to perform the maintenance on all of the items scheduled for maintenance. Warehouses are not excluded from this responsibility and shall report all defects to the relevant maintenance department by creating a defect or any other relevant request.

• The warehouse staff shall ensure that the person performing the maintenance inspection duly signs and files the maintenance record, which is to be kept by the Senior Warehouse Supervisor for audit purposes.

• The equipment shall be selected and designed to accommodate the specific requirements of the goods stored and to ensure safety, ease of access to, and retrieval of, goods.

• No employee should ride on equipment used for the moving, handling, or storage of material, unless it has been designed for the purpose.

• All equipment should be operated in a safe and efficient manner and should not be loaded beyond the capacity for which it was designed; the weight capacity of the equipment needs to be displayed on the equipment.

• Material handling equipment is susceptible to fire from friction heat generated by accumulations of grease and dirt. Fires involving forklifts can be caused by equipment failure due to lack of maintenance. All such equipment should be inspected regularly and maintained in good working order.

3.14 Safe storage and material handling principles

3.14.1 Stock levels

• Storage systems should not be operated beyond their design capacity.

• The maximum tonnage/quantity of stock that can be safely stored should be known, and different parts of the organisation (purchasing, warehousing, etc.) should cooperate to ensure that overstocking does not occur.

• There should be systems in place for monitoring stock levels (by regular inspection/audit), and arrangements should be made to store excess volumes safely in emergency or overflow stores.

3.14.2 Containment

• Storage systems should be properly designed to contain products within the storage area and prevent materials from falling into gangways or parts of the workplace.

• All materials should be suitably contained/restrained to prevent unexpected movement.


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3.14.3 Lifting and handling

• Only lifting equipment that meets the requirements of the Driven Machinery Regulations should be used.

• Bundles should not be lifted by the banding material.

• All lifting operations should be planned and supervised.

• Equipment must be regularly examined and properly maintained.

3.14.4 Load marking

• Clear markings and notices should be used to indicate weights of products.

3.14.5 Safe access

• Adequate means of safe access, suitable and properly maintained floors/walkways, and safe gangways should be provided to allow employees to work in safety in a safe environment.

• Gangways should be at least 900 mm wide.

• Door openings should be wide enough to accommodate forklifts, where required.

• Vehicles and pedestrians should be kept apart, whenever possible.

• When used by pedestrians, gangways should be at least 900 mm wide.

3.14.6 Safe place of work

• Lifting and handling equipment should be designed, as far as is reasonably practicable, to allow employees to work (for example, to sling and handle loads) from a safe position (such as a gangway).

• People should not be required to climb up into, or walk on, stacked materials or storage racking.

• High-risk areas (for example, loading and unloading, materials receiving, materials storage, order preparation, process, issuing/dispatch) should be clearly defined and unauthorised people kept out.

3.14.7 Splitting of bundles

• During order picking, it may be necessary for bundles to be broken down into smaller amounts.

• Bundles should not be split at height, nor when stored in a normal storage rack.

• Splitting should only be done in a safe place at ground level or in a restraint/cradle/rack designed for the purpose.


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3.14.8 Deliveries/collections

• Stock deliveries should be properly planned and details shared with all relevant staff.

• All parties (for example, suppliers, hauliers, and customers) should cooperate to ensure that the plans are prepared and implemented by trained, competent staff.

• The health, safety, and welfare of drivers delivering to any Eskom premises shall be taken into consideration.

• Goods must be stacked to prevent movement during transportation and be secured so that they will not fall off when corners or inclines and declines are being negotiated.

• Precautions must be taken to protect workers in the storage area against moving vehicles. If necessary, a responsible employee should be designated to direct traffic in the storage yard or area.

• Wearing of reflective clothing will increase visibility while in the yard areas.

• All mechanical-operated equipment should be fitted with horns and lights, and these should be used, especially when reversing.

3.15 Manual handling

3.15.1 Manual handling shall be avoided, where possible. Where such operations are necessary and cannot be avoided, the following measure should be applied:

• Assess the risk.

• Make sure that employees know the risk and how to control it.

• Determine ways of reducing the risk of injury as far as is reasonably practicable.

• Review assessments as and when appropriate.

3.15.2 The risk assessment should cover the full range of manual handling operations where there is risk of injury. This will include the majority of situations in which stock is handled. The risk will be increased by:

• the handling of particularly heavy stock;

• holding loads away from the body;

• long carrying distances;

• strenuous pushing and pulling;

• twisting, stooping, or reaching upwards;

• sudden movement of the load;

• the handling of unstable loads or those likely to shift;

• loads that are difficult/awkward to grasp;

• the handling of sharp edges; and


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• working in awkward environments (for example, where there are space constraints, uneven or slippery floors, variations in floor levels, working outdoors, or when lighting is poor).

3.15.3 A decision to handle stock manually should not be taken by workers themselves. It should always be specified following a suitable and sufficient risk assessment that identifies the precautions needed to reduce the risk of injury to the lowest level reasonably practicable.

3.15.4 The risk can be reduced by:

• avoiding dangerous manual handling;

• avoiding barring off; and

• training employees to avoid the risk.

3.15.5 Because of the size, weight, and shape of most stock, manual handling will often involve a significant risk of musculoskeletal disorder (MSD).

3.15.6 Transport, storage, and handling systems must, therefore, be planned, designed, and installed to eliminate the need for high-risk manual handling operations, wherever possible.

3.16 Rules for safe stacking

3.16.1 Safe stacking of free-standing materials requires:

• avoidance of stacking where there is any doubt about a product’s inherent stability; • use of an appropriate stacking system; for example, the types of checks or battens

used; the stacking pattern and the maximum stack height should be appropriate for the material being stacked, taking account of any likely stack failure modes;

• adherence to safe systems of work; • minimising the time people spend working within a given stack or passing between

adjacent stacks; and • avoiding materials being moved while people are within, or near, the stack.

3.16.2 Safe organisation of storage areas:

• Adequate arrangements should be made to protect people and limit the spread of material in the event of a stack collapse (for example, through the use of protected walkways and suitable intermediate/end supports).

• Adequate arrangements should be made to protect stacks from impact damage by vehicles (for example, through the use of suitable supports).

• Safe access should be provided on all sides of a stack to allow for the safe slinging of loads.


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3.16.3 Safe stack support:

• Each stack should stand on a solid and level surface (for example, concrete or railway sleepers), ideally mixed with only one product, and be neat, level, and vertical.

• If products are mixed within a stack, they should be compatible for storage, and smaller materials should be placed on larger materials.

• If battens are used, they should be made from square sections of a suitable, resilient material (so that stacks are always level), placed directly above those in the lower levels of the stack, and positioned so that there is no undue bow or sag in the product.

3.17 Safe stock movement

3.17.1 Goods must be stacked to prevent movement during transportation and be secured so that they will not fall off when corners or inclines and declines are being negotiated.

3.17.2 Precautions must be taken to protect workers in the storage area against moving vehicles. If necessary, a responsible employee should be designated to direct traffic in the storage yard or area.

3.17.3 Good lighting is essential, and the wearing of reflective clothing will increase safety.

3.17.4 All mechanical-operated equipment should be fitted with horns and lights, and these should be used, especially when reversing.

3.18 Segregation of stock

3.18.1 Flammable liquids, gas cylinders, aerosols, materials liable to spontaneous combustion, and hazardous chemicals should not be stored in the same area as other goods.

3.18.2 Chemicals liable to react with one another or other materials should not be stored together, unless adequately protected from making contact with one another, either directly or through spillage.

3.18.3 Acids should not be stored in plastic containers for long periods or in direct sunlight.

3.18.4 Flammable liquids in drums, cans, or similar containers should be stored separately in a separate area or building constructed for the purpose. Similar provision is recommended when storing toxic or poisonous chemicals or substances.

3.18.5 Acids should not be stored in plastic containers for long periods or in direct sunlight


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3.18.6 Flammable liquids in drums, cans, or similar containers should be stored separately in a separate area or building constructed for the purpose. Similar provision is recommended when storing toxic or poisonous chemicals or substances.

3.18.7 The storage area or building should be signposted to indicate that it contains flammable or hazardous chemical materials and that smoking and naked flames are prohibited.

3.18.8 Electrical equipment used in or around the storage area or building should be suitably explosion-protected, and protective equipment should be provided nearby for use in emergencies.

3.18.9 Workers handling corrosive or hazardous chemicals should be provided with suitable protective clothing or other necessary safeguards.

3.18.10 Liquefied and compressed gas cylinders should be stored in well-ventilated areas, out of direct sunlight, and well away from possible sources of ignition, especially electrical fittings or fuse boxes.

3.18.11 All containers, drums, and cans should be clearly labelled with their contents.

3.18.12 Earthing or bonding should be used to eliminate the possible build-up of static electricity.

3.19 Shelf life

3.19.1 A proper management system should be implemented to manage shelf-life items.

3.19.2 Shelf-life items should be properly identified and labelled as shelf-life items. The storage locations allocated to these items shall be clearly marked, indicating that FIFO should be applied to them.

3.19.3 The material numbers for UV-sensitive products are marked for shelf life when created in SAP (MB5M).

3.19.4 The material shall be flagged for batch management in the SAP storage view.

3.19.5 Strict FIFO principles are to be adhered to.

3.19.6 UV-sensitive products shall be:

- stored in a dark, humidified, and temperature-controlled room;

- individually packed in non-static packaging; and

- visually inspected on SAP notification (MB5M).


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3.20 Training of employees

3.20.1 Employees involved in the storage, stacking, loading, and unloading of materials must be trained to carry out their tasks safely and efficiently in accordance with the prescription of the supplier, any legislative requirements, or any applicable Eskom policies, directives, and procedures.

3.20.2 They should be made aware of the nature of the goods stored, the hazards involved and the precautions to be taken, protective clothing and equipment to be worn, the care, use, and maintenance of such clothing and equipment, and the action to be taken in emergencies.

3.20.3 Employees operating mechanical equipment need special training for the particular types of equipment used and must be issued with a licence to operate the equipment on successful completion of the relevant training.

3.20.4 The correct method of dealing with breakages or spillages and neutralising hazardous chemicals and substances should also be explained.

3.20.5 Fire safety, including the use of firefighting equipment, should be part of all training.

4. Acceptance

This document has been seen and accepted by:

Name Designation

Kerseri Pather General Manager Sustainability Division

Alex Stramrood Senior Manager Sustainability Systems OHS

Sivi Govender Middle Manager OHS Governance and Compliance

Chris Tosen Chief Advisor Material Management

Pierre du Toit Senior Manager Supply Chain

OHS Steering Committee

SHEQ Managers

Sustainability Systems Business Advisors

5. Revisions

Date Rev. Compiler Remarks May 2015 1 TJ Mabeleng A new standard with reference

number 240-93411424 was developed in line with Eskom documentation requirements.


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6. Development Team

The following people were involved in the development of this document:

• C Tosen

• WJ Swanepoel

• HE Viljoen

• G Botha

• J Moodley

• B Gama

• W Kinsella

• M Tafeni

• T Mabeleng

• J Phakola

7. Acknowledgements

N/a.


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APPENDIX A: INSPECTION FREQUENCIES

ITEM EXAMINATION/INSPECTION FREQUENCY

Lifting equipment, for example, cranes Daily before use by operator and other checks in accordance with manufacturer’s recommendations and Driven Machinery Regulations.

Lifting accessories, for example, chains, slings, ropes, forklift chains

Daily before use by operator and other checks in accordance with manufacturer’s recommendations and Driven Machinery Regulations.

Racking systems (including SWL notices, etc.) Daily before use by operator and weekly/monthly visual inspections.

Thorough inspections at least annually.

Access equipment, for example, mobile safety steps

Daily before use by operator and monthly visual inspections.

Floors, guide rails, barriers Daily before use by operator and regular visual inspections.

Correct use of storage systems Daily before use by operator and monthly visual inspections.

Safe storage arrangements for lifting attachments

Daily before use by operator and monthly visual inspections.

Table 1: Mandatory and recommended inspection frequencies for key equipment/systems

stacking and storage standard functional area: e · pdf filedocument template 32-4 revision 7...

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