Installation, use and maintenance, risk assessment manual, Slot … · • CNR UNI 10011/97 and CNR 10022/84 • Italian Decree Law 81/2008. Marcegaglia is currently enhancing its

Installation, use and maintenance, risk assessment manual

Slot-in shelves system Light Bi-Bloc

Instruction manual • Light Bi-Bloc1

Contents

GENERAL OVERVIEW

General rules for the use of Light Bi-Bloc storage system

Construction and assembly tolerances

Limits of supply and use

Applicable standards

User’s liabilities

Maximum permissible loads

List of components

ASSEMBLY STEPS

Installation phases

Tightening torque tables

CORRECT MAINTENANCE GUIDELINES

Scheduled maintenance plan

HAZARD IDENTIFICATION, EVALUATION AND ASSESSMENT

Semi-quality scales

Hazard class ranking

2

3

4

4

4

6

8

10

14

17

18

18


General information

GENERAL RULES FOR THE USE OF LIGHT BI-BLOC STORAGE SYSTEM

UseLight Bi-Bloc is the ideal solution for the storage of goods in bulk.

Th e system is made of vertical elements called uprights, and horizontal

elements called beams; these, fi tted with tiles to form shelves, allow the

storage of bulk goods, as well as boxes and small packages.

Goods must be placed on shelves in a way that ensures good balance

and stability.

Two-sides shelving structures allow to effi ciently use available spaces.

Light Bi-Bloc is compatible with automated installations.

OverloadsIt is strictly forbidden to load racks beyond the maximum load allowed.

Load limits can be found on signalization panels or technical specifi ca-

tions, such as blueprints or brochures. It is also required to verify maxi-

mum permissible loads upon contract forms.

As a general rule, the maximum weight allowed for horizontal parts of

the structures (beams, platforms and side-guards) refer to the “evenly

spread load” standard.

Indeed, a very localized load or an unbalanced load yet within the limit,

may jeopardize the overall stability of a structure.

Dynamic loadsLoads must be soft ly placed on racks, avoiding rough handling or unu-

sual horizontal shift s.

Structures that will be subject to special dynamic conditions, such us

free-fall supply storage areas or in case of rugged environmental condi-

tions causing exposure to winds, snow loads or even earthquake must

be specially designed.

Technical characteristics and materials (standard)• Upright frames height:

• Upright frames depth:

• Beams nominal length:

• 200-mm tiles nominal length:

• 100-mm tiles nominal length:

• Safety: beam stopper

• Uprights: Sendzimir galvanized steel S350GD Z200 UNI EN 10326

• Stringers/diagonals: Sendzimir galvanized steel S280GD Z200 UNI

EN 10326

• Beams: Sendzimir galvanized steel S350GD Z200 UNI EN 10326

• Tiles: Sendzimir galvanized steel S280GD Z200 UNI EN 10326

• Base plates: steel S235JR UNI EN 10025 electro-galvanized

Variations in layoutWherever some modifi cations to the basic design are required, this

must involve a study of feasibility so to ensure that load parameters on

each section of a rack and the rack itself as a whole are fi t to withstand

new load conditions.

Whenever beam platforms are removed or in case of a greater headro-

om clearance that may become necessary in order to store bulkier load

units, upright loads might be eff ected, resulting in a hindered loading

capacity. Please contact the technical offi ce at Marcegaglia for custo-

mized design.

Storing goodsDiff erent storing options for Light Bi-Bloc shelves include totally auto-

mated handling or mechanical handling.

Th e correct storage procedure requires the goods are centered and uni-

formly distributed on the shelf, avoiding unbalanced loads and over-

turning.

CollisionsIn no way, manipulation vehicles shall bump into the racks. In case

of accidental damages, their extent must be carefully assessed and all

components being eff ected must be replaced.

In case of frequent similar accidents or bumps, it is highly recommen-

ded to install crash barriers by the racks.

Staff trainingTh e warehouse foreman must receive detailed technical information

about the storage capacity and features.

Each rack or component maximum load is detailed on both lay-out

blueprints and the load capacity panels that come with the rack itself.

Th ere is some basic information that must be spread and made available

to all personnel, including:

• Maximum load for each couple of beams

• Maximum load for each upright frame

• Distance between two loading levels

Staff must be trained to:

• use the handling equipment correctly

• inform those in charge immediately in the event of collisions with

structures

• inform those in charge of any malfunctions noted

• use the personal protection equipment during installation, mainte-

nance and handling operations

Forbidden proceduresTh e following are forbidden on warehouse storage systems supplied by

Marcegaglia:

• welding

• fi tting of ties for use for installing systems of any kind

All such operations must be included in the installation design and

approved in writing by Marcegaglia.


Tolleranze di montaggio per verticalità scaff ali e fl essione travi

K = ± 10 mm

e = ± 10 mm

H = Rack height

L = Beam length

a = Net shift along Z-axis

b = Net shift along X-axis

c = Beams positive defl exion

d = Beams negative defl exion

e = Vertical tolerances along Y-axis

K = Single upright tolerances, resultant of deformation,

inclination and shift ing of the upright basis

CONSTRUCTION AND ASSEMBLY TOLERANCES

b k

k

H

Y

X

Y

Xa k

c

d e

L

a [mm] b [mm] c [mm] d [mm]

H H500

H1000 _ _

L _ _ L200

L * 0.7200


LIMITS OF SUPPLY AND USE

Light Bi-Bloc has been designed for indoor applications, within indu-

strial buildings.

Specially designed racks can be supplied for outdoor use, whenever

racks are exposed to winds, snow or placed in seismic areas.

Racks will be placed on a reinforced concrete fl oor, laid down by the

buyer. Said fl oor must be adequately fl at, with a tolerance of +/- 1 cm

and must be suitable to withstand the rack driven loads.

Whenever fl oors are laid upon a lower store’s ceiling, its load and defor-

mation must be carefully verifi ed and compared with the rack weight.

Attention must be focused on concentrated spot loads.

Floors in materials other than concrete are not recommended and must

be the subject of careful consideration during design of the Light Bi-

Bloc.

Th e load on shelving systems must not exceed the values in the load

rating signs, which must always be affi xed in a position clearly visible

to operatives.

MANUFACTURING STANDARDS

At the design stage the following laws and regulations have been

observed:

• CNR UNI 10011/97 and CNR 10022/84

• Italian Decree Law 81/2008.

Marcegaglia is currently enhancing its product range to comply to the

following European Norms:

UNI EN 15629:2009 dates 19/03/09

Steel static storage systems - Specifi cation of storage equipment.

UNI EN 15635:2009 dates 19/03/09

Steel static storage systems - Application and maintenance of storage

equipment.

USER’S RESPONSIBILITIES

Light Bi-Bloc users have a number of specifi c responsibilities with re-

gard to the assurance of conditions of compliance.

Th ey are responsible for:

• compliance with the regulations in the country of installation;

• compliance with the supplier’s detailed assembly and installation in-

structions, which must be followed correctly when installation is car-

ried out by the user or its contractor;

• compliance with specifi cations concerning the maximum weight and

overall dimensions of the goods or load units for storage;

• compliance with limits concerning anchoring to the ground, even-

ness of fl oor, fl oor load-bearing capacity, etc.;

• clearly showing the load limitations of handling equipment including

lift s and forklift s;

• care not to drag or push goods when in contact with the warehouse’s

structural elements;

• the provision of the essential recommended turning spaces, to mini-

mise the risk of collision between loads, or between loads and the ware-

house storage fi ttings;

• the use of equipment compliant with the contract specifi cations;

• the fi tting of guards on the uprights where necessary;

• regular inspections of Light Bi-Bloc rack throughout its working life

to ensure that any damage is repaired and damaged components are

replaced with new parts supplied by the same producer;

• the use of staff skilled in the use of the handling equipment and the

proper storage of load units upon the pallet racks, to ensure safe opera-

tion of the system.


6

MAXIMUM PERMISSIBLE LOADS

Upright framesUpright frames are formed by two uprights of equal length (formed

from 1.5-mm or 2-mm thickness steel sheet) connected by means of

stringers and diagonals, fi xed with bolts. Uprights have slots at regular

interaxis for beams connection.

• By maximum permissible load we mean an evenly distributed weight

between two framed uprights. Unbalanced situations such as weights

leaning depth-wise must be carefully evaluated.

• “H” is the height where the fi rst beam is placed, starting from the

fl oor, or the beam base along the height, wherever it is larger. In case of

a larger base between beams height-wise, such portion of the rack must

be verifi ed keeping such base as “H” value.

• Each span must feature 2 pairs of beams along the height in order to

maintain longitudinal stability. In case of jointers (extended upright

frames) 3 pairs of beams are required.

• When assessing profi les, all weights leaning on the ground locked

pair of beams will not be considered.

BeamsBeams are one-piece steel shaped profi les provided with 4-hook upright

connection plates at each end.

TilesTiles are made from shaped steel sheets.

MAXIMUM PERMISSIBLE UPRIGHT FRAME LOADS

BEAM INTERAXIS (mm)

S55/45B(kg)

S55/55B(kg)

600 4600 6500

900 4200 5800

1200 3700 4700

1500 3200 4100

1800 2900 3900

2100 2400 3200

MAXIMUM PERMISSIBLE LOADS PER BEAM COUPLE

Standard beams for tiles 100 and 200

CODE NOM. LENGHT L = mmQ LOAD

(kg)WEIGH

(kg)

3681900895 1200 1195 800 2,70

3681901485 1500 1490 770 3,35

3681902085 1800 1790 600 4,02

3681902475 2000 1985 480 4,45

3681903275 2400 2385 320 5,33

MAXIMUM PERMISSIBLE FOR TILES

TILES 200 LTB CODEL =

ACTUALLOAD

u.d.l. (kg)WEIGHT

(kg)

LBB-TILE 200 x 400 Th. 0,6 ZZ 3683020805 414 130 0,563

LBB-TILE 200 X 500 Th. 0,6 ZZ

3683021005 514 115 0,699

LBB-TILE 200 x 600 Th. 0,6 ZZ

3683021205 614 100 0,835

LBB-TILE 200 x 800Th. 0,6 ZZ 3683021605 814 80 1,107

LBB-TILE 200 x 1000Th. 0,6 ZZ 3683022005 1014 60 1,379

LBB-TILE 200 x 1200 Th. 0,6 ZZ 3683022405 1214 50 1,651

TILES 100 LTB CODEL =

ACTUALLOAD

u.d.l. (kg)WEIGHT

(kg)

LBB-TILE 100 x 400 Th. 0,6 ZZ 3683010805 414 130 0,373

LBB-TILE 100 X 500 Th. 0,6 ZZ

3683011005 514 115 0,463

LBB-TILE 100 x 600 Th. 0,6 ZZ

3683011205 614 100 0,553

LBB-TILE 100 x 800 Th. 0,6 ZZ 3683011605 814 80 0,733

LBB-TILE 100 x 1000 Th. 0,6 ZZ 3683012005 1014 60 0,913

LBB-TILE 100 x 1200 Th. 0,6 ZZ 3683012405 1214 50 1,093


Shelves load capacityShelves are intended as a couple of beams fi tted with tiles.

LOAD CAPACITY LIGHT BI-BLOC SHELVES WITH TILES 200, THICKNESS 0,6

NOM. L. (mm)

ACTUAL L. (mm)

N. OF TILES BEAMS LOAD

CAPACITY

UPRIGHT FRAME DEPTH (mm)

200 100 400 500 600 800 1000 1200

1000 995 5 0 800 650 575 500 400 300 250

1100 1095 5 1 800 715 633 550 440 330 275

1200 1195 6 0 800 780 690 600 480 360 300

1300 1295 6 1 800 800 748 650 520 390 325

1400 1395 7 0 800 800 800 700 560 420 350

1500 1490 7 1 770 770 770 750 600 450 375

1600 1590 8 0 740 740 740 740 640 480 400

1700 1690 8 1 660 660 660 660 660 510 425

1800 1790 9 0 600 600 600 600 600 540 450

1900 1990 9 1 520 520 520 520 520 520 475

2000 1985 10 0 480 480 480 480 480 480 480

2100 2085 10 1 430 430 430 430 430 430 430

2200 2185 11 0 400 400 400 400 400 400 400

2300 2285 11 1 360 360 360 360 360 360 360

2400 2385 12 0 320 320 320 320 320 320 320

2500 2485 12 1 300 300 300 300 300 300 300

LOAD CAPACITY LIGHT BI-BLOC SHELVES WITH TILES 100, THICKNESS 0,6

NOM. L.(mm)

ACTUAL L.(mm)

N. OF TILES BEAMS LOAD

CAPACITY

UPRIGHT FRAME DEPTH (mm)

200 400 500 600 800 1000 1200

1000 995 10 800 800 800 800 800 600 500

1100 1095 11 800 800 800 800 800 660 550

1200 1195 12 800 800 800 800 800 720 600

1300 1295 13 800 800 800 800 800 780 650

1400 1395 14 800 800 800 800 800 800 700

1500 1490 15 770 770 770 770 770 770 750

1600 1590 16 740 740 740 740 740 740 740

1700 1690 17 660 660 660 660 660 660 660

1800 1790 18 600 600 600 600 600 600 600

1900 1990 19 520 520 520 520 520 520 520

2000 1985 20 480 480 480 480 480 480 480

2100 2085 21 430 430 430 430 430 430 430

2200 2185 22 400 400 400 400 400 400 400

2300 2285 23 360 360 360 360 360 360 360

2400 2385 24 320 320 320 320 320 320 320

2500 2485 25 300 300 300 300 300 300 300


Beam with safety stopper

Upright frame

Tiles

List of components

Base plate


Shelf (side view)Shelf


INSTALLATION PHASES

Axis drawWhen starting assembly axis must be drawn, by actually drawing on

the fl oor some boxes representing the required lay out of one-sided and

double-sided racks.

Assembling the columns1) Install the base plate by means of the upright screw hole.

2) Install the stringer inserting the spacing element on the fi rst hole

(where no diagonal is jointly inserted).

3) Insert locking screws in every hole on uprights and diagonals.

4) Go ahead and install all diagonals that are needed in order to com-

plete an upright frame.

5) Upright frame assembly is completed.

Installation

52

1 4

3


Setting upright frames verticalSet the structures vertical by levelling the base plates, adjusting their

height as necessary.

Assembling the beamsInstall at least 4 beams for each span, at the height indicated by the

project.

Secure connections with beam stoppers.

VERTICALITY: v<H/1000

v = Longitudinal and side out-of perpendicularity

H = Structure height

ALIGNMENT: a = ± 5 mm

a = Maximum structure drift lengthwise and sidewise.

HORIZONTALITY: o = ± 5 mm

o = Maximum drift of fl at parts, when compared with

the original blueprint.

Remarks:

Equipment tolerances are given case by case.


Assembling the tilesCompose shelves with tiles.


Anchoring to the groundFix the base plates by means of expansion plugs according to the dia-

gram:

Load capacity signsFit the load capacity signs in a visible position (installation main entran-

ce, loading bay entrance).

ONE-SIDED RACKS

Maximum height (mm) according to the number of expansion plugs for each base plate and upright frame depth B (mm)

N. exp. per base plate B = 400 B = 500 B = 600 B = 800 B = 1000 B = 1200

0 (1200) * (1500) * (1800) * 2200 3200 3200

1 (1900) * 2200 2700 3700 4700 4700

2 2200 3200 3700 4700 6200 6200

2 + upper anchoring 6000 7200 8200 8200 8200 8200

TWO-SIDED RACKS

Maximum height (mm) according to the number of expansion plugs for each base plate and upright frame depth B (mm)

N. exp. per base plate B = 400 B = 500 B = 600 B = 800 B = 1000 B = 1200

0 2200 2700 3200 3700 4500 4500

1 3200 4200 4700 5200 6200 6200

2 4200 5700 6200 7200 8200 8200

2 + upper anchoring 8200 8200 8200 8200 - -

• Tables consider measures up to the maximum standard upright height = 8200 mm

• For higher upright sizes, anchoring must be calculated in the project

• Where anchoring with 1 fi ller plate per base plate, cross the anchoring of upright frame

B = 400-500-600-800-1000-1200

EXPANSION PLUGS

BR-b M 8x70

80

11

* With NON-standard upright frames


TIGHTENING TORQUE TABLES

• Comply strictly with the manufacturers’ instructions with regard to

the tightening torques of the mechanical expansion plugs.

• UNI 5737 hex head screws and similar bolts, UNI 5931 Allen screws.

• Friction coeffi cients on shank and threads u=0.14 (black phosphate

screws, oil before fi tting).

• Torque applied gradually with torque wrenches,

not impact screwdrivers.

• When tightening with impact screwdrivers, reduce torque M by 10%.

• For cadmium screws, reduce torque M by 20%.

• For wide hex head screws, increase torque M by 5%.

MINIMUM TIGHTENING TORQUES FOR SHEAR JOINTS,WITH CLASS 8.8 SCREWS

d(mm)

Area(mm2) Ts (N x m) = 8,8

5 14 3

6 20 5

8 36 12

10 58 20

12 84 45

14 115 72

16 157 112

18 192 154

20 245 218

22 303 298

24 353 350

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Constant, systematic checks are required to ensure that the structures remain in good condition over time.

Scheduled maintenance table

DESCRIPTION OF OPERATION

FREQUENCY PROCEDURE TOOLS TO BE USED

Inspection for collision damage

From 6 months to one year

Check regularly for permanent dents of varying extent caused by collisions.On systems with a high turnover rate, a thorough visual inspection should be performed every 6 months.For other systems, the inspection can be performed annually.The damaged parts must be replaced with genuine components.

Check that structureis vertical

Every 2 years Checks that the structures are vertical must be performed by inspecting the structures of both ends of the system in both directions (lengthways and crossways).Consider the assembly tolerances stated in the manual.Restore structures to the vertical position using shims.

Inspectionof anchoring to the foundations

Every 2 years Check the tightening torque of the expansion plugs. Torque wrench calibrated at an authorised laboratory.

Tightnessof bolts

Every 3 years Check 10% of bays, evenly distributed over the various zones of the drive-in system.In the event that more than 5% of the bolts checked are not properly tightened, proceed to check 50% of bays.In the event that more than 10% of the bolts checked are not properly tightened, proceed to check 100% of bays.At the next inspection, check the bays not checked the time before.

Torque wrench calibrated at an authorised laboratory.

Inspectionof galvanisedand painted fi nishes

From oneto 5 years

Check the condition of the galvanised or painted fi nishes at a frequency decided depending on the installation location: in corrosive environments, inspect every year; in normal indoor environments, the inspection interval may be as longas 5 years.

Instructionsfor proper maintenance


Th e method adopted for the identifi cation of risks is based on the

identifi cation of processes involved in the construction of the sys-

tem.

Th e risks were identifi ed for each process, and then evaluated on the

basis of the legal requirements and the rules of good practice, the en-

vironmental context, and the simultaneous and/or consecutive pres-

ence of diff erent contractors and/or diff erent processes.

Semi-qualitative scalesRisks were assessed with the aid of the two semi-qualitative scales:

• D index scale: indicates the potential damage related to the risk

• P index scale: indicates the probability and frequency with which an

event may occur

For allocation of the values 0,1, 2 and 3, the occurrence of even just one

of the conditions stated in the “criteria” column is suffi cient.

Naturally, the allocation of one of the values does not imply a prediction

that all the conditions corresponding to the value chosen, listed in the

“criteria” column, will apply.

Risk identifi cation, analysis and assessment

Assignment of risk categoriesTo assign a risk category, the two indicators, D and P, must be corre-

lated by placing them on Cartesian axes and taking the value assig-

ned on a sectorial basis as reference:

Risk categories are assigned as follows:

A-SLIGHT: Risk conditions for which the monitoring of the potential ha-

zards has to be maintained or implemented.

B-MINOR: Risk conditions for which monitoring of the potential ha-

zards has to be established to identify any increase.

C-MODERATE, D-HIGH: Risk conditions for which preventive and pro-

tective measures have to be adopted to reduce the risks in relation to the

degree of risk identifi ed.

D INDEX (POTENTIAL DAMAGE) SCALE

VALUE CRITERIA

3

Damage causing irreversible injuries(death, anatomical and/or functional loss).Injuries producing temporary disability with initial prognosisof recovery in > 40 days may occur.There is a correlation between the procedureand the possibility of death or permanent disability.

2

Injuries producing temporary disability with initialprognosis of recovery in > 21 days may occur.There is a correlation between an accident during a stageof the process and the risk of injury with partial or total stoppage of operations lasting > 30 days and/or the production of limited environmental contamination.

1

Injuries producing temporary disability with initial prognosisof recovery in ≤ 21 days may occur.There is a correlation between an accident during a stageof the process and the risk of injury with partial or total stoppage of operations lasting > 1 and ≤ 30 days.

0

Injuries producing temporary disability with initial prognosisof recovery in ≤ 3 days may occur.There is a correlation between an accident during a stageof the process and the risk of injury with partial or total stoppage of operations lasting ≤ 1 day.

P INDEX (PROBABILITY - FREQUENCY OF EVENTS) SCALE

VALUE CRITERIA

3

There is a direct correlation between the risk factor and the cause related to a form of damage.Damage has already occurred due to the problem identifi ed (accidents, injuries, occupational illnesses).There is a correlation between the procedure and/or the risk factor and the deterioration of the accident rate and/or the rate of occupational illness over a signifi cant period (three to fi ve years). The likelihood of an accident is ≥ 2*10-2

2

The risk factor may cause damage, although not automatically or directly.Occasions on which the problem noted has led to the damage are recorded.There is a correlation between the procedure and/or the risk factor and a random trend in the accident rate and/or the rate of occupational illness over a signifi cant period (three to fi ve years). The likelihood of an accident is < 2*10-2 e ≥ 3*10-3

1

The factor may only cause damage in occasional circumstances or due to an unlucky combination of events.No occurrences are known, or they have been rare.There is a correlation between the procedure and a positive trend in the accident rate and/or the rate of occupational illness over a signifi cant period (three to fi ve years).The likelihood of an accident is < 3*10-3 e ≥ 3*10-5

D IN

DE

X

(PO

TEN

TIA

L D

AM

AG

E) 3 C D D

2 B C D1 A B C0 A A B

1 2 3

P INDEX (PROBABILITY OR FREQUENCY OF EVENTS)


MARKING OF UPRIGHT FRAME OUTLINES ON THE FLOOR

OperationMarking of the outlines of the upright frames on the fl oor (laying of

“marker lines”).

Work placePlace where the shelving system is installed.

x Type of riskPossible interference, to be assessed on a case-by-case basis, with ac-

tivities carried out at the same time (e.g. installation of electrical or air-

conditioning systems, masonry fi nishing operations).

Preparations and equipment required to guarantee compliance with the regulationsTh e requirements to be met for compliance with the regulations must

be assessed on a case-by-case basis depending on the characteristics of

the place of installation.

Performance proceduresTo be decided on a case-by-case basis depending on the characteristics

of the place of installation.

TRANSPORTATION OF LIGHT BI-BLOC COMPONENTS TO THE WORK SITE

OperationUnloading of shelving system components from the truck.

Work placeAs specifi ed in plan.

x Type of riskSmall metal parts (metal fasteners, etc.) striking workers.

Preparations and equipment required to guarantee compliance with the regulationsSuch loads must only be lift ed using metal buckets or bins;

the use of open platforms or slings is not permitted (art. 58 of Italian

Presidential Decree 164/56).

Performance proceduresInforming of workers with regard to the procedures to be adopted when

lift ing (raising and lowering) loads.

If the material for unloading is not in small pieces, bundles of sections

or other materials may be lift ed with two slings of the same length with

the aiding of lift ing machinery (e.g. a truck-mounted crane).

Damage index: 2

Probability index: 2

Risk index: C

x Type of riskBruises to the head.

Preparations and equipment required to guarantee compliance with the regulationsUse of hard helmet.

Damage index: 2


Risk index: C

x Type of riskBruises to the feet.

Preparations and equipment required to guarantee compliance with the regulationsUse of puncture resistant safety footwear.

Damage index: 2


Risk index: B

x Type of riskCuts or grazes to the hands.

Preparations and equipment required to guarantee compliance with the regulationsUse of protective gloves.

Damage index: 1


Risk index: B

x Type of riskBack injury.

Preparations and equipment required to guarantee compliance with the regulationsAssess loads during this stage. In general, if the average weight lift ed by

a person is more than 25 kg, there is a risk of back injury.

Depending on the company, this general statement must be backed up

by a risk assessment (pursuant to Italian Decree Law 81/2008) bearing

in mind all parameters (actual weight of the load, handling conditions,

frequency, etc.) required to provide a complete risk assessment.

If risks of this kind are actually identifi ed, the employer (contractor

performing the installation) must fulfi l all the obligations required by

Decree Law n. 81/2008, (health monitoring, information and training

of workers).


Damage index: 2


Risk index: C

STORAGE OF LIGHT BI-BLOCCOMPONENTS

OperationCreation of a storage area for the materials.

Work placeTo be specifi ed in the plan.

x Type of riskMaterial falling onto people.

Preparations and equipment required to guarantee compliance with the regulationsTh e materials must be placed or stacked in such a way as to prevent col-

lapse or overturning (Decree Law 81/2008). Use helmets and puncture

resistant safety footwear.

Performance proceduresProvide the workers concerned with instructions on the way in which

the materials are to be stacked and where to stack them.

Damage index: 2


Risk index: C

x Type of riskFire caused by fl ammable materials (paints, solvents, etc.).

Preparations and equipment required to guarantee compliance with the regulationsEven small amounts of fl ammable materials (paints, solvents) must be

stored away from sources of heat, equipment which causes sparks, and

electrostatic discharges, and must be in sealed containers.

No smoking signs must be provided in the places where these materials

are stored.

A class 13A - 89BC powder fi re extinguisher must be provided in the

store containing this material. If more than small amounts of fl amma-

ble materials are present, the number of extinguishers must be increa-

sed, and units with extinguishing capacity of at least 21A 89BC must

be installed.

If, for example, the quantity of paint exceeds 500 kg, fi re prevention

certifi cation must be applied for (point 20 of Ministerial Decree of

16/2/1982). Th e access door to the store must have a raised threshold to

prevent leaks.

A ventilation opening should be provided (as a guideline, at least 1/100

of the fl oor area of the room).

Damage index: 2


Risk index: B



Damage index: 1


Risk index: B

ASSEMBLING THE UPRIGHT FRAMES

OperationAssembly of the various elements which make up the upright frames

using bolts, and transfer of the assembled upright frame from the work-

surface (trestles) to the storage position (which may be temporary depo-

sit in the installation site).

Work placeAs specifi ed in plan.

x Type of riskNoise exposure

Preparations and equipment required to guarantee compliance with the regulationsNoise assessment (Decree Law 277/91).

Performance proceduresTh e use of ear plugs or ear defenders is recommended when using an

electric screwdriver (as a precautionary measure).

Damage index: 2


Risk index: B




Performance proceduresDraw up a procedure for the manual handling of the upright frames

on the basis of the results of the health monitoring operations and the

characteristics of the loads (NIOSH regulations).

Damage index: 2


Risk index: B



Damage index: 2


Risk index: B

x Type of riskBack injury due to the manual handling of loads.

Preparations and equipment required to guarantee compliance with the regulations Assess loads during this stage. In general, if the average weight lift ed by

a person is more than 25 kg, there is a risk of back injury.

Depending on the company, this general statement must be backed up

by a risk assessment bearing in mind all parameters (actual weight of

the load, handling conditions, frequency, etc.) required to provide a

complete risk assessment.

If risks of this kind are actually identifi ed, the employer (contractor

performing the installation) must fulfi l all the obligations required by

Decree Law n. 81/2008, (health monitoring, information and training

of workers).

Damage index: 2


Risk index: C

x Type of riskInjury due to the exposure of the upper limbs to vibration during the

use of electric or pneumatic screwdrivers.

Preparations and equipment required to guarantee compliance with the regulations In general, the vector sum of the accelerations measured on the three

axes in normal conditions of use exceeds 5 m/s2.

In the scientifi c literature, this value is accepted as the “trigger thresh-

old” above which preventive and protective measures must be taken.

In this case, the use of vibration-damping gloves and health monitoring

must be enforced.

Damage index: 2


Risk index: C

x Type of riskKnocks to the head.

Preparations and equipment required to guarantee compliance with the regulationsUse of protective helmet.

Damage index: 2


Risk index: C

x Type of riskElectrocution due to the use of electric screwdrivers.

Preparations and equipment required to guarantee compliance with the regulations Portable devices (electric screwdrivers) must have double insulation

(class II) identifi ed by the symbol of two concentric squares. Power

supply sockets must be fi tted with a device which prevents accidental

removal of the plug. Unsecured plug sockets may be used provided they

comply with the CEI 23-12 “Industrial plug sockets” standard.

Unsecured plug sockets and their power supply cables must be protec-

ted against mechanical damage.

Cables laid temporarily must be fl exible (H07 RN -–F) with rubber in-

sulation with polychloroprene (PCP) or equivalent sheathing. Whether

unsecured or permanently mounted, plug sockets must have at least

IP44 protection. In particularly hazardous work site environments

(presence of water, etc.) use of a higher degree of protection (IP55 or

IP67) should be considered.

Portable devices must be connected to an electricity supply system fi t-

ted with a high-sensitivity diff erential safety breaker having tripping

threshold Id of 30 mA or below; a single diff erential safety breaker may

protect up to 6 sockets on the same panel.

For overload protection, a magnetothermic switch must be installed

for each socket, unless the power supply to the panel is protected by

a single magnetothermic switch having rated current the same as the

lowest of the rated currents of the plug sockets.

Th e power supply panel must have protection appropriate to the envi-

ronment where it is used (at least IP43).

Damage index: 3



Risk index: C

TRANSPORTATION OF UPRIGHT FRAMES AND SHELVING TO THE INSTALLATION SITE

OperationTransfer of assembled upright frames, beams and bolts by fork-lift truck

from store to installation position.

Work placeRoute from store to installation site.

x Type of riskHitting of workers with parts of the upright frames which project from

the fork-lift truck during transport.

Preparations and equipment required to guarantee compliance with the regulationsProvide traffi c lanes of suitable width for the dimensions of the load and

the characteristics of the work site.

Safety helmets must be worn both by the fork-lift truck driver and the

workers on the work site.

Damage index: 2


Risk index: B


the fork-lift truck during transport.

Preparations and equipment required to guarantee compliance with the regulationsPlace the load on the fork-lift truck in accordance with the instructions

provided by the truck’s manufacturer, to ensure that it does not fall off

in transit.

Improve the driver’s front view by placing the transported load, in ac-

cordance with the instructions provided by the manufacturer of the

fork-lift truck, in such a way that it does not obstruct the lines of vi-

sion needed for safe driving (note that an incorrectly positioned load

distracts the driver’s attention, meaning that he pays less attention to

any people present in the vicinity). Anyone assigned to follow the tran-

sported load from close at hand should wear a high-visibility vest.

Damage index: 2


Risk index: B

x Type of riskOverturning of the fork-lift truck.

Preparations and equipment required to guarantee compliance with the regulationsEnsure that the fork-lift truck driver receives suitable training;

Th e driving position must have appropriate protection against crushing

in the event that the truck overturns (in general, this protection is pro-

vided by fi tting the truck with an enclosed cab).

When reversing, fork-lift truck drivers must be assisted by a person

on the ground.Passengers must not be carried unless permitted by the

truck’s manufacturer in the driver’s cab.

Damage index: 3


Risk index: C

x Type of riskImproper use of the fork-lift truck.

Preparations and equipment required to guarantee compliance with the regulations No workers who have not received the information, training and in-

struction required by the relevant regulations must be allowed to use

fork-lift trucks.

Damage index: 1


Risk index: B

x Type of riskAccidental operation of load handling controls.

Preparations and equipment required to guarantee compliance with the regulationsFor fork-lift trucks placed on the market, and/or put into service before

Presidential Decree no. 459/96 came into force, and which do not have

the CE marking pursuant to the “Machinery Directive”.

• All load control devices must have automatic return to the idle position;

• Load control devices must be of the “hold-to-run” type and operated

by electrical, mechanical or other systems;

• Load control devices must be placed and arranged in such a way that

they cannot be accidentally operated, especially with regard to the spe-

cifi ed route for access to the vehicle’s driving and control position (see

Ministry of Labour and Social Security Circular no. 50/98).

For fork-lift trucks with CE marking, the measures specifi ed above do

not apply, since this marking confi rms that the manufacturer has com-

plied with the essential safety requirements for the machine (Presiden-

tial Decree no. 459/1996).

Damage index: 2


Risk index: C


x Type of riskShearing or crushing of parts of the operator’s body by parts of the fork-

lift truck moving in relation to each other.

Preparations and equipment required to guarantee compliance with the regulationsChains, sprockets or other moving parts in any way accessible to the

drivers or others must be fully protected by means of guards.

As an alternative to these guards, “safety distances” between moving

parts are equally acceptable (see Ministry of Labour and Social Security

Circular no. 50/98).

Damage index: 2


Risk index: C

x Type of riskNoise exposure.

Preparations and equipment required to guarantee compliance with the regulationsTh e use of ear plugs or ear defenders is recommended (as a precautio-

nary measure).

Damage index: 2


Risk index: B

UPRIGHT FRAME ASSEMBLY WITH THE LOWER LEVEL OF BEAMS

OperationLift ing upright frames and locking them with the fi rst beam row.

Work placeAs per layout.

x Type of riskHands cuts or bruises.

Preparations and equipment required to guarantee compliance with the regulationsUse protection glove.

Damage index: 2


Risk index: B

x Type of riskFoot bruises.

Preparations and equipment required to guarantee compliance with the regulationsUse steel sole toe shoes.

Damage index: 2


Risk index: B

x Type of riskBack and lumbar damages because of manual manipulation of loads.

Preparations and equipment required to guarantee compliance with the regulationsAssess loads during this stage. In general, given the average weight of

the upright frames (90-150 kg) it can be stated that there is a risk of

back injury.

In this case the employer (contractor performing the installation) must

fulfi l all the obligations required by Decree Law no. 81/2008, (health

monitoring, information and training of workers).

Damage index: 2


Risk index: C

x Type of riskRisk of being hit by falling or dropped materials.

Preparations and equipment required to guarantee compliance with the regulationsUse hard hats.

Damage index: 3


Risk index: C

x Type of riskRisk of being hit by collapsing unbalanced uprights due to mishandling.

Performance proceduresDraw up a appropriate assembly procedure, complete with any hand

signals for communications (see Decree Law 493/96).

Damage index: 3



Risk index: C


Damages cause by upper limbs exposures to vibrations cause by an elec-

tric or air-powered screw-driver

Preparations and equipment required to guarantee compliance with the regulationsIn general, the vector sum of the accelerations measured on the three axes

in normal conditions of use exceeds 5 m/s2. In the scientifi c literature,

this value is accepted as the “trigger threshold” above which preventive

and protective measures must be taken. In this case, the use of vibration-

damping gloves and health monitoring must be enforced.

Damage index: 2


Risk index: C

x Type of riskElectrocution caused by an electric screwdriver.

Preparations and equipment required to guarantee compliance with the regulationsSee operation page 21

ASSEMBLING BEAMS AND OTHER ACCESSORIES AT UPPER LEVELS (including rear barrier, if any, side or rear protective grille)

OperationInstallation of vertical bracings at height above 2.0 m.

Work placeAs envisaged by the design.


Preparations and equipment required to guarantee compliance with the regulationsUse of protective gloves..

Damage index: 2


Risk index: B



Damage index: 2


Risk index: B

x Type of riskBack injury due to the manual handling of loads.

Preparations and equipment required to guarantee compliance with the regulationsAssess loads during this stage. In general, since the average weight of

the elements handled is 20 kg (to be subdivided by the two workers who

assemble the parts), the risk of back injury can be considered to be un-

der control and therefore acceptable.

If a risk of this kind is actually identifi ed, the employer (contractor per-

forming the installation) must fulfi l all the obligations required by De-

cree Law no. 81/2008, (health monitoring, information and training of

workers).

Damage index: 2


Risk index: B

x Type of riskInjuries due to falling objects.

Preparations and equipment required to guarantee compliance with the regulationsUse of safety helmet for both the assigned workers and for other workers

present during the operation (also those from other companies).

Damage index: 3


Risk index: C

x Type of riskFall from height.

Preparations and equipment required to guarantee compliance with the regulationsUse of motorised and other equipment allowing work to be carried out

using platforms fi tted with parapets.

Working cages lift ed by lift ing equipment may also be used within the

limits set by art. 184 of Presidential Decree no. 547/55 and further to

the installation of eff ective cage (or basket) safety devices as envisaged

by Ministry of Labour and Social Security Circular no. 103/98.


A properly anchored safety harness can be used only where the use

of equipment of this kind is not possible (e.g. during installation with

aisles less than 1.70 – 1.50 metres wide).

Damage index: 3


Risk index: D

x Type of riskInjury due to the exposure of the upper limbs to vibration during the

use of electric or pneumatic screwdrivers.

Preparations and equipment required to guarantee compliance with the regulationsSee operation page 21.

PAINTING OF SMALL AREAS OF METAL COMPONENTS

OperationPainting with paints or enamels.

Work placeShelving system.

x Type of riskInhalation of harmful chemicals (solvents).

Preparations and equipment required to guarantee compliance with the regulationsFollow the instructions provided in the product safety information; in

all cases, a facial half-mask with A2 fi lter is recommended.

Damage index: 2


Risk index: C

x Type of riskContact between skin and harmful chemicals (solvents, paints).

Preparations and equipment required to guarantee compliance with the regulationsFollow the instructions provided in the product safety information;

in all cases, chemical-resistant gloves should be worn.

Damage index: 2


Risk index: C

x Type of riskKnocks to the head from collisions with shelving system elements.


Damage index: 2


Risk index: B

x Type of riskFoot crushing or puncturing.


Damage index: 2


Risk index: B

x Type of riskFire or explosion.

Preparations and equipment required to guarantee compliance with the regulationsDo not carry out painting jobs while open fl ames are used, or sparks or

electrostatic charges are generated, in the vicinity.

Do not leave paint containers open.

Damage index: 2


Risk index: B

ASSEMBLING GROUND LEVEL COMPONENTS

OperationAnchoring of metal elements to the fl oor.

Work placePlace where the shelving system is installed.

x Type of riskInhalation of dust generated by use of drills.


Preparations and equipment required to guarantee compliance with the regulationsUse of protective masks.

Damage index: 2


Risk index: B

x Type of riskExposure to the noise produced by drills.

Preparations and equipment required to guarantee compliance with the regulationsEarplugs or noise-proof headset as recommended (pre-emptive measures).

Damage index: 2


Risk index: B

x Type of riskKnocks to the head from collisions with shelving system elements.


Damage index: 2


Risk index: B



Damage index: 2


Risk index: B

x Type of riskElectrocution due to the use of electric screwdrivers.

Preparations and equipment required to guarantee compliance with the regulationsSee operation page 21

VERTICALITY CHECKS AND INSPECTIONS FOR CORRECT INSTALLATION

OperationInspection of Bi-Bloc sections, including high locations.

Work placeRack.

x Type of riskPrecipitation.










Damage index: 3


Risk index: D

x Type of riskHead bumps against rack elements.

Preparations and equipment required to guarantee compliance with the regulationsUse hard hats.

Damage index: 2


Risk index: C




Damage index: 2


Risk index: B

TESTING OF LIGHT BI-BLOC

OperationInspection of Bi-Bloc sections, including high locations.

Possible loading test.

Work placeRack.

x Tipologia di rischioPrecipitation.










Damage index: 3


Indice di rischio: D

x Type of riskRisk of being hit by materials placed on racks during load tests.

Preparations and equipment required to guarantee compliance with the regulationsUse of protective helmets; fencing of the entire area involved with movable

barriers and placing of a suitable number of warning signs stating “No pe-

destrian access” or “No unauthorised access”, as appropriate.

Damage index: 2


Risk index: C


Preparations and equipment required to guarantee compliance with the regulationsFoot crushing or puncturing.

Damage index: 2


Risk index: B


Notes

via Giovanni della Casa, 1220151 Milano - Italytel. +39 . 02 30 704 1 fax +39 . 02 33 402 [email protected]

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Codice manuale: 00000000SQMANING10 edizione Febbraio 2010 - rev.0

Documents

Installation, use and maintenance, risk assessment manual, Slot … · • CNR UNI 10011/97 and CNR 10022/84 • Italian Decree Law 81/2008. Marcegaglia is currently enhancing its