Heavy Plates - light forklift

[BoxAndGo]

How do I skid twenty steel plates that are 250" x 80" x 1/4" . Each plate is 1400lbs.

I have a 5000# limit forklift. Need ideas!!

[Admin]

Hi BoxAndGo,

Welcome to the WCO forums!

Full disclosure for readers: BoxAndGo asked about us about this job over the phone and we recommended he post the question here in the forums so we can share the info with others. So my answer may cover more than the question.

And a disclaimer: Be safe. I'm recommending a few 'tricks'. Be sure your load is secure on the forklift.

The answer may not lie so much in how to crate or skid, but more in generally how to get it there.

Questions to be considered are:

• Are they all going to the same destination or different ones?
• How are they being transported and what's their final destination?
• Are they generally self-supporting or allowed to flex, or do they have to be kept rigid? (I assume if they're steel that they can flex)
• How is your work space laid out? In what direction do they need to be laid to get them out the door?
• What resourced are available at the other end? Do they have a larger forklift? What capacity? If they're going out of the country, strongly consider that they may need to be sling lifted.
• How cost sensitive is the customer?

I would start by going to the standards page and take a look at the MIL-HDBK-701 which covers skidding. This is probably the easiest US standard to understand. (Which doesn't mean it's real easy to understand.) Flip through it and take a look at the tables near the middle of the pdf. It will tell you what size materials to use.

Next, if they're all going to different destinations or two each to a destination, you can follow the directions in the 701 handbook and put two per skid. If they're going to the same destination, then you have to consider more options. After considering the resources they have at the destination, get as many plates on one skid as possible, otherwise just take the info below and stack the skids. If you stack the skids, you may need to add some timbers to create guides so that the skids stack correctly and stay in place.

Assuming that the ideal goal is to get them all on one skid, see if you can get a flatbed or container (whatever is necessary) dropped off in the morning so you can have time to load it. The idea here is to first identify the lifting capacity and method at the other end and then work based on that. For example, if they'll be sling lifted by a crane, you'll probably go with a flatbed, if not, maybe a container or trailer. An issue with a shipping container or trailer though is the weight and the center of balance. Since the plates are so long, you will, and the receiver may have difficulty loading/unloading it. A flatbed may be ideal otherwise, I would opt for a container over a trailer if possible.

The big thing to consider is to build the skid and put it in place empty, then load the plates onto the skid. That way, you don't have to deal with your 5000# forklift limitation. Or, you may want to assemble the skid on the flatbed or in the container. After the skid is in place, load the plates on one-at-a-time. You will need to use fork extensions, but I assume that you have some already. If not, you should consider them as standard equipment.

If you need to load them into a trailer or container, you'll either have to deal with lifting them from the end or getting the entire skid in at once. If you have to lift them from the end, you can still do them one-by-one. First, be sure the plate is up on blocks so you can get under it, then place something heavy (like a loaded crate - ideally about 3000# but you'll find what works) and put it on the plate at the end you're going to lift from. This will be a counter balance. Lift each plate and slide it onto the skid/other plates. This way, you're never exceeding your forklift capacity.

If you don't have anything to counterbalance them, build a temporary dolly that can hold about 5000#. Make it high enough to go over the top of the skid and put it under the leading edge of the plates then pick up the other end and roll the plates to the skid. Get the edge of the plates on the skid then lift them and pull the dolly out. If you go this route, either start with one plate or be sure the skid is designed with runners that you can slide the plates onto.

Also consider if you need to put blocking between the plates. It may be OK to just use a forklift to slide them over one-at-a-time so you can get forks underneath them, but the customer may not like that or it may damage the plates so you'll need to add some blocking.

That should cover the basics so lets talk about blocking...

This may be difficult to explain without a drawing. Three issues come to mind when it comes to blocking:

• Aligning up the plates while you are loading them onto the skid
• Blocking between plates if they need to be separated
• Strong load stabilization

For aligning the plates while loading them: In any situation, you will need to have blocks bolted to the skid around the outside edges of the plates. So since the plates are 250" x 80", I would assure that I have skids and runners that line up with the edges, so you want to assure you have strong members that are about 80-1/4" across from OUTSIDE edge to OUTSIDE edge and also about 250-1/4" across in the other direction. Cut them to length to go all the way from the ground to flush with the top plate. I would probably use 4x4s with 3/8" carriage bolts. If anything, go bigger.

Put two vertical blocks at each end and two or more on the sides. The sides may be an issue if loading into a shipping container or trailer. If you use vertical blocks, you may have a hard time sliding the plate in-between them. If you think this will be a problem, consider running 4xN" most of the length or in long segments so the plates have more of a track to slide in. If you have a couple extra guys, you can probably just go with the verticals instead of making a track and have them push the plates in place. If you have guys in the container helping, I would NOT put the skid all the way to the front of the container. There's not enough room on the sides to be safe so they'll likely have to stand in front of the skid.

Next, you'll need to assure the plates are held down. If they only go by ground in a trailer, a fast stop could run the plates right through the trailer wall. If in a container, you'll have a mess at the other end to say the least. If they go by sea, imagine someone picking them up and throwing them against the roof in the container. Unless they go by flatbed on one skid and assuming you only have 5000# strapping you'll want to strap the plates to the skids MANY times in both directions. If you use 5000# strapping use AT LEAST (assuming all plates are on one skid) 8 straps in each direction (16 total) assuming one skid. Consider putting two across each pair of vertical blocks. You'll get a lot more strength by leveraging the blocks.

If you need to block between plates, I would put a 2x4" flat every 4 feet and no more than 2 feet from the ends. Remember that they have to stay on top of each other. I would put them between the vertical blocks mentioned above. Here's a particularly difficult to explain part... Use 4x4 vertical blocks to hold the plates stacked properly (at mentioned above) then 2x4x80" between them, then nail 2 each 2x2x6" into the edges of the 4x4 on each side of the 2x4. So, you'll use 4 each 2x2x6" for each 2x4x80" You will need to install the 2x2"after loading each plate to assure the 2x4 is aligned properly. You don't need much horizontal holding power and the 2x2s should break away during unloading if necessary (as is desired).

Be sure the carrier knows about the load and the number of skids. If it must go in a trailer, post back and I'll give a recommendation for stacking, otherwise the driver should be able to handle the load stabilization.

I think I covered everything. If anyone else has other or better ideas, please post them. I'd like to compare my ideas to others.

[BoxAndGo]

Thanks! I'll spend some time and review all this and see if I need to provide more information.