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Selecting Industrial Guard Rail

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Selecting Industrial Guard Rail SELECTING INDUSTRIAL GUARD RAIL TECHNICAL WHITE PAPER Executive summary What do people think when they hear the term guard rail? Is it something on an elevated platform that prevents people from falling? Is it that low-profile metal strip that runs along the freeway? Or maybe nothing significant comes to mind? Unfortunately, the latter is often the case, especially when talking about guard rail in an industrial setting. Guard rail is one of those components in a facility that typically is not top of mind with companies, until it’s too late. Soft federal guidelines for guard rail use have helped contribute to its low awareness within facilities, and have placed the on us for use on individual companies to implement. When used properly, guard rail can effectively protect equipment, assets and personnel in and around a facility. The key is to identify areas in need of guard rail, correctly specify it for the application, and take action. The purpose of this white paper is to establish the need for guard rail, show the differences in materials, testing and ratings for guard rail, and to demonstrate how Wildeck’s multiple guard rail offerings can provide the right level of protection while protecting your budget. 2 SELECTING INDUSTRIAL GUARD RAIL Why guard rail? While industrial guard rail protects machinery and Place an inexperienced driver behind a forklift provides a safe and efficient work environment, and the risks increase. Well positioned guard rail its most important role is protecting people. can help reduce the chance of accidents by keeping Forklifts, tugger AGVs and other material handling forklifts and other vehicles from entering hazardous vehicles are commonplace in manufacturing or off-limits areas. facilities, and often operate in close proximity to employees. Sometimes their paths do cross—with While there are OSHA guidelines regulating the deadly results. According to the Occupational use of hand rail and other guarding devices in Safety and Health Administration (OSHA), there facilities for structures such as stairs, mezzanines, are about 85 fatal forklift accidents per year in the temporary manhole covers etc, there is no direct United States; 34,900 accidents that result in serious guidance for the use of guard rail around machinery injury, and about 61,800 accidents that are classified or designated vehicle travel paths. As such, many as non-serious. Additionally, slightly less than half facilities simply mark the floor for off-limit areas, of the estimated 85 annual fatal forklift accidents travel paths and pedestrian walkways with occur in manufacturing facilities; of that about 10 yellow-striped tape—which provides absolutely percent involve people getting struck or run over no protection against vehicle impact. What happens by a forklift. if the forklift driver experiences a medical issue, such as a heart attack, or is inattentive to his How do forklift accidents happen? OSHA says surroundings due to texting on his cell phone? that most accidents could have been prevented A yellow piece of tape will certainly not stop an with better operator training. Still, it’s easy to see out-of-control forklift. how an accident can occur. Many manufacturing facilities have tight lanes for forklifts to drive. If a turn isn’t executed properly, the wheels or forks could stray into a designated safe area occupied by employees or expensive equipment. TECHNICAL WHITE PAPER 3 Differences in guard rail Although it may look similar in appearance, not all rated guard rail, it typically deflects only 10 inches guard rail is made the same. Many manufacturers or less. A few inches may not seem that great, build guard rail to have an impact rating of 10,000 but in facilities and distribution centers where pounds traveling at 4 mph. An average forklift with space is often a premium, those few extra inches a load generally weighs between 8,000–10,000 mean that closer equipment and fixtures will be pounds. Guard rail with a 10,000 pound impact protected and additional manufacturing or storage rating means it should prevent a forklift from driving space can be obtained. It’s important to check the through the guard rail at a speed traveling at 4 mph impact rating on any guard rail purchased. That’s or less. The goal of industrial guard rail is to maintain because some manufacturers don’t list an impact its integrity and deflect an impact. In contrast, highway rating for their guard rail. The likely reason is guard rail is designed to absorb and disperse an impact, that it was never tested or it failed an impact test, which is why at an accident scene that type of guard and they didn’t want to spend the time, money or rail is typically crumpled up. resources to redesign it. So they go to market with a product that isn’t rated. These are guard rails to But sometimes a 10,000 pound impact rating may avoid because their impact rating isn’t known. not be enough. Some manufacturers, like Wildeck, build guard rail to a stronger 13,000 pound impact rating. The added value that a higher-rated guard rail brings to a facility is an increased level of safety and peace of mind. Clearly, a higher-rated guard rail will withstand a more severe impact. Furthermore, 13,000 pound impact rated guard rail has a lower deflection rate than 10,000 pound guard rail. For example, when a forklift strikes 10,000 pound impact rated guard rail traveling at 4 mph, it can deflect, or push back, up to 12-15 inches. When that same forklift strikes 13,000 pound impact 4 SELECTING INDUSTRIAL GUARD RAIL Building 13,000 pound impact rated guard rail The way some suppliers achieve a 13,000 pound impact rating is found in their manufacturing process. Wildeck’s research shows that the best material to use is corrugated 11 gauge steel for the rails. In the manufacturing process, strength is also gained by hemming the top and bottom portion of the rail sections. This step both provides added strength and smooths out any sharp or rough edges, enhancing employee safety. Many Certified testing manufacturers do not hem the rails and simply cover up rough edges with a plastic strip that can The purpose behind certified testing of guard rail easily fall off over time. Strength is also added in is to demonstrate and prove that it is actually able to the columns and base plates. Structural tubing handle and deflect the specified amount of weight post columns should measure 5" x 5" with a 3/16" that it was designed to withstand. Wildeck enlists wall thickness, and be robotically welded to a the services of a registered professional engineer heavy-duty base plate measuring at least 12" x 12" to oversee its testing process to preserve integrity. with a thickness of 3/4". For maximum strength, avoid weaker columns that measure 4" x 4", and In testing 13,000 pound impact rated guard rail, two base plates that only measure 10" x 10" with a guard rail assemblies were bolted to a 5" x 5" x 3/16" thickness of 1/2". For assembly, rails should be column. The base plate was 12" square and 3/4" bolted to the inside of each column, not the front. thick; base plate holes measured 5/8" in diameter. Many manufacturers bolt rails to the front of the The column assemblies were properly secured to column, exposing sharp jagged edges. a concrete floor using four 1/2" diameter x 4-3/4" long Rawl anchor bolts. TECHNICAL WHITE PAPER 5 A 12,700 pound forklift with a 200 pound driver Of course once an accident occurs, facility managers was driven into a marked midpoint on the guard quickly see the value that protective guard rail can rail traveling at 4 mph. provide. But the importance of installing guard rail to protect people and equipment prior to an accident The resulting impact showed that the guard rail seems to be resonating with companies. Despite did its job and successfully stopped the forklift’s fluctuations in the economy, sales of protective guard forward progress. The guard rail was permanently rail have increased. One rationale is that since deflected at both the lower and upper rails, but the companies don’t have the resources to purchase new measured permanent deflection was only 5-3/4" on equipment, they’re looking to protect what they the bottom rail and 4-3/4" on the upper rail. The have, and guard rail is a relatively inexpensive way anchors on the columns remained in place, and to provide that protection. In many facilities there there was no damage to the columns in the areas can be various protection requirements, which is of the rail-mounting holes. While both rails were why Wildeck now offers three types of guard rail damaged and would have to be replaced, both systems, each rated to provide a level of impact maintained their structural integrity and protected protection ideally suited to meet specific safety everything beyond the deflection of the rails. If this and budget needs. level of impact protection is desired, specifying a 13,000 pound rated guard rail is your best choice. Wildeck can perform an audit of equipment in either a new or existing facility, and recommend solutions Changing perceptions on how and where to best use guard rail to protect personnel and equipment. In a facility with equipment A manufacturer can design and build the best guard that can sometimes be valued at more than a million rail in the world, but what good does it serve if it’s dollars, properly protecting with a tested guard rail not being used.
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