Rack Repair BEWARE!

• Why can’t we simply weld a stiffener channel to the damaged rack column?

• Racks already have welds when I buy them, why can’t we do the same?

• Do you have anything in writing from OSHA about onsite welding on existing racks?

These are all legitimate questions for someone looking

to fix their racks but getting a clear answer on what is acceptable and what is not, isn’t easy. OSHA is not specific about rack damage or repairs; they ask that rack damage be addressed so that no one gets hurt and remain unclear about how this should be done.

The Rack Design Code (ANSI MH16.1), states that “welds on the test specimen shall satisfy and be performed in strict conformance with the requirements of Welding Procedure Specifications (WPS) as required by the American Welding Society (AWS)”. But this is aimed towards rack manufacturers, not the rack’s owner or maintenance manager.

The Rack Repair Guidelines issued by RMI are more explicit about welding. They outline that field repairs (in the warehouse) are risky and must be overseen by a qualified Professional Engineer so that the work is performed in accordance with applicable American Welding Society (AWS) codes.

They also talk at length about field welding risks such as fire hazard, weld contamination, operation temperature, engineer supervision and welder certification. I’ll summarize these for you:

Fire hazard: even when carefully following recommended fire safety procedures, welding causes sparks that may fall in the worst possible places, on products, flammable product or pallets, and become a fire hazard. Consult OSHA standard 29 CFR 1910.252(a) for more details.

Weld contamination: this happens when the welded surfaces are not well prepared, which can result in a weakened weld or hydrogen embrittlement, possibly leading to failure.

An excerpt from AWS: “…The portions of such surfaces which will be welded shall be thoroughly cleaned of all foreign matter including paint for at least 2 in [50 mm] from the root of the weld.” (1)

Operation temperature: great care must be taken to control the temperature during the welding process to respect AWS standards. Welding in a freezer environment is therefore generally discouraged.