After assessing a damaged rack section, a qualified, professional rack engineer may determine that a rack repair kit will work, as opposed to field welding. That’s because, as outlined in Appendix 1 of RMI’s publication “Guideline for the Assessment and Repair or Replacement of Damaged Rack – Version 1,” there are several risks associated with field welding. These include fire, potential for weld contamination and the work performed in an improper ambient temperature, compromising the weld.
With those field welding risks in mind, the majority of RMI manufacturers offer “bolted” upright frame repair kits. These engineered kits may allow for removal of damaged sections of rack. Then, a properly designed, like-new product that has been properly designed and bolted in place, eliminating the complexities associated with a welded repair.
About Rack Repair Kits
Before undertaking a kit-based rack repair, it’s important to understand that kits do not include standard, off-the shelf components. Instead, an engineer designs them to match the configuration and loading of the existing rack at the location of the damage. Their creation takes into account all the loads being imparted upon the damaged component—not solely upon the particular member being repaired. Further, a separate evaluation of each load configuration is necessary. Also, the engineered repair kit must meet applicable building codes.
In non-seismic areas, a properly-engineered repair kit might include:
- A thicker or reinforced column
- A splice at mid-height between the shelves and above the damage
- A splice design that is stronger and stiffer than the original column
- A frame bracing pattern that continues from the floor to just below the splice
- A baseplate that is stiffer and with more robust anchorage
Seminar Highlights Repair Kits
RMI’s recent ProMat 2019 on-floor educational seminar, “Storage Rack Safety 101,” highlighted rack repair kits. One of the points noted was that a kit must maintain frame bracing continuity. That means it must match the bracing of the original rack design and have a continuous load path from above the splice to below the splice. When determining the appropriate column splice for a given repair, engineers have a choice of two styles:
- A splice designed to bear the load when integrated into the racking system.
- A splice that utilizes heavy-duty bolts to bear the load.
Moreover, when placing the new column base on the floor, the installer should anchor it using different holes than the previous plate. This ensures proper anchoring to the floor. If any open holes remain in the floor, placing new anchors 3-bolt-diameters (center-to-center) away from an empty hole will secure the column without reducing its pullout capacity. For holes filled with dry-pack mortar, install a new anchor 1.5-bolt-diameters (center-to-center) from the filled hole.
Engineering Review Recommended
Although third-party aftermarket kits and services are available, it is critical to have an engineer familiar with rack—or its manufacturer—review and approve a third-party’s proposed kit’s design to ensure its installation preserves the structural adequacy of the original system.
To ensure that the rack repair kit used to replace damaged racking components, best practice is to work with the original rack manufacturer and a qualified engineer. This enables a rack owner to be confident that the repair work will be fully compatible with the current system and continue to provide a safe working environment for their workers.
Upon the repair of any rack structure—whether by the original equipment manufacturer or a third-party—a professional rack engineer must update the Load Application and Rack Configuration (LARC) drawing. These updates show the fabrication and installation details and all repair locations. The engineer must also sign and seal the new LARC. Doing so indicates their approval of the whole rack system with the repair kit installed.
Find Out More About Fixing Damaged Rack
Want to learn more about rack repair? Download RMI’s Guideline for the Assessment and Repair or Replacement of Damaged Rack – Version 1.
