PUSHBACK RACKING INSTALLATION MANUAL

For Health World Limited Project (2 Pallet Deep)

1.0 INTRODUCTION
This document serves to outline the proper Pushback Racking installation
procedures with
control and safety measures. All site personnel will be trained in the
aspect of the work to
be under taken by suitably qualified and experienced persons who will act
as supervisors
to ensure safe methods of working and provide clear and comprehensive
instructions.

2.0 WORKMANSHIP AND INSTALLATION PROCEDURES

The installers shall complete the works in strict accordance with the
specification and
drawings provided and shall comply with all written instructions and
directions given from
time to time by the engineer.
2.1 Site Survey
The installation supervisor must survey the site prior to the actual
installation to check for
building utilities which include electricity (sockets and fuse ratings, proper
lighting)
generator set, water, comfort rooms and all available erection equipments
such as hoists,
lift platforms etc. The temporary staging or pre-assembly area must also
be checked as
well as the safest storage location.
The area in which the racking is to be erected should be checked in
relation to the
dimensions shown on the drawings and informs the engineer of any errors
or omissions
like dimensional inaccuracies from the drawings.
The assembly area must be clean and free from any obstructions like
construction
materials, rubbish, incomplete HVAC ductworks, existing racking or
shelvings, exposed
electrical wirings etc. The condition of the floor must also be checked to
prepare
beforehand the type of leveling required, i.e. shimming, grouting etc.
2.2 Materials Handling & Transporting to Site
Before the materials are dispatched to site, a checklist must be completed
confirming the
quantity, dimensions and profiles of the steelwork with reference to the
project BOM. The
condition of each parts and components must also be checked like
straightness, finishing,
welding etc. Checking will be done by warehouse personnel together with
designated

installer-checker. Steelworks shall be handled, stored, lifted and

transported by methods
which will not overstress or deform the members nor damage their
protective coatings.
All materials should be properly marked with removable or erasable
markers not to
damage the protective coatings and cause permanent indentation on the
surfaces.
2.3 Delivery Route / Temporary storage of materials
Delivery route will be checked and discussed with the client on site to see
which is the
best and safe. Delivery route will also be re-discussed if there is any
change when
unplanned situation occur. Temporary storage of materials will be stored
as per
arrangement with the occupier of the premises. Materials will be
barricaded for any
access into it.
2.3 Laying-out and Floor Marking
Locate the datum point in the plan drawing, normally with reference to the
side walls,
building column or corner, and layout the datum line or reference line as
start point of the
installation. Floor markers may be a hard chalk or soft stone or any other
marking material
that can be erased easily and will not caused permanent marks.
2.5 Installation Sequence
Prior to start date of installation there must be a clearance to proceed
from the client and
or its representative or the building contractor. The date of delivery of
items on site must
have been agreed by both parties the installation team will establish an
operational base
on site.
All job details including layout and manufacturing drawings, bill of
materials (BOM) to be
presented in full to the installation supervisor prior to job start. Studying
and
understanding the assembly drawing is essentially importance since it can
increase the
efficiency and minimize the mistake during the installation.
2.6 Site Observation
Accuracy of the building layout plan need to be compared on the actual
building site to
ensure better storage systems settled up. Any obstruction to storage
systems such as
fire-hose, electrical switch box, pipe, over-head crane, truss, air-con duct
etc.

Ceiling height and lighting clear height. Building items that are not shown
on the drawing
layout plan such as window, emergency exits, overhead crane, ceiling
beam, goods cargo
lift etc.
Types of condition of the floor level. Wall straightness between walls to
wall that run
parallel to each grid. Any existing racking or shelving, which would appear
obstruction to
the installation

3.0 INSTALLATION PUSHBACK RACKING

The Project Manager must initiate a meeting to brief all installers on a
systematic
sequence of the work. Every installer must be assigned to do a specific
work in order for
him to use his time more effectively.
Figure

3.1 Step 1 Installation of Pushback Racking Frames

The Racking frame consists of the following components: Upright Post,
Base Plate and
Bracing. Each frame will be pre-assembled at the staging area. Start by
securing the
frames to the ground at the rear of the lane. Start by assembling the
lowest lane and work
upwards. Secure the beams of the two lowest levels to stabilize the
structure. The overall

frame depth is 2440mm (838mm + 764mm + 838mm).

3.2 Step 2 Installation of Pushback Beams

Beam Clear Entry is 2600mm. Pushback beams are supplied automatically

adjusts the
slope of the pushback rails to 2%. Please make sure that each type of
beam is installed in
the right place in accordance with the layout drawing SML/2/2818. There
are 6 different
types of pushback beams, which are PSB1, PSB2, PSB3, PSB4, PSB5 and
PSB6. Start
by determining the height settings on the ground which 1st floor level
beam is 2045mm.
The 2nd beam level is 3745mm, 3rd beam level is 5445mm and 4th beam
level is 7145mm.
Racking must be attached to ground so that Pushback Racking is stable
and rigid, before
installing the pushback rails and carts.

3.3 Step 3 Installation of Pushback Rails

Once pushback beam per level are installed, then start by assembling
pushback rails in
the lowest level and work upwards. Insert the pushback rails on the
beams. Position 4

pushback rails in each clear entry. One pair set on the left and another
pair set on the
right. Check that the lift-out guides face outwards. Check that the centreto-centre
distance between the pushback rails matches the distance shown on the
layout drawing
supplied. Please adjust the position of the pushback rails as per layout
drawing.
For box beams (PSB2, PSB3, PSB5 and PSB6) are installed at the middle of
the lane,
use the fixing to attach the pushback rails to the box beams. Once the
pushback rails
have been secured on the lowest level, climb onto these pushback rails to
secure the rails
on the next higher level. Always wear a harness and a hard hat in order to
move about the
installed pushback rails in safety

Figure 5: Installation of Pushback rails

Figure 6: Installation of Pushback rails

3.4 Step 5 Installation of Pushback Carts

Take a set of pushback cart using the forks of the forklift. Deposit the set
of pushback cart

on the pushback rails. The forks of the forklift must be suited to the length
of the
Pushback carts. Make sure you do not damage the rails and carts during
installation. Test
the lanes with pushback cart whether moving properly on rails as one by
one as they are
assembled. Make sure that the available height between two levels
complies with the
specifications of the rack. Always meet the specifications of the rack
(height between two levels.

4.0 NOTES ON SAFETY

4.1 No manager can afford to ignore safety of pushback pallet racking
installation and to
ensure that the recognized element of safety are maintained, all installers
must be
briefed accordingly prior to the actual installation.
4.2 There must be a proper lighting in the workplace and premises.
Enough daylight
reaches worksites without being shadowed by obstacles or wrong worksite
positions
during pre-assembly of plan bracings.
4.3 Avoid wearing tight fitting working clothes as they hinder smooth
physical movements
required by the work. Protective clothing such as hard hat, gloves and
safety shoes
must be worn during disassembly and conversion work.
4.4 Choose tools of appropriate size and shape for easy and safe use.
Hand tools can be
gripped without undue pressure on tissues and joints. They should be of
good quality
and well maintained. Replace tools before they wear out.
4.5 Access routes/ aisles should have a guard barrier where there is risk of
falling. Use
adequate types of personal protective equipments. Storage of goods must
not be
started before all assembly work is completed. The installation area must
be
barricaded with signage Off-limits or No Access.
4.6 Identify the protective measures required concerning risks related to
the local
conditions at the site and to usage. Always wear suitable Personal
Protective
Equipment (gloves, safety shoes, safety harness, hard hat, etc.) during
assembly.
Define a safety zone under the working area.
4.7 The assembly and installation must be carried out by qualified
personnel in
compliance with the instructions concerning assembly and installation,
and with

safety instructions.
4.8 Clean the work site at the end of the installation. Do not leave any
components or
tools in the installation area. Make sure that the plastic straps linking the
carts to one
another are removed.
4.9 Schafer shall not be held liable for any malfunctions if the rack is not
properly
installed. Consider special purpose tools for repeated actions. Installation
procedures
based on common sense are very important. ALWAYS Safety first!!!