Storage rack manufacturer information and descriptions of their products.
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In this chapter, we examine the concept of storage racks and outline the essential considerations when designing and selecting them.
Storage racks, commonly referred to as racking systems, are structures intended for storing various items and materials. These systems generally consist of two or more vertical frames, horizontal beams, and decking components which may include bars, panels, meshes, or may not contain decking at all.
When creating storage racks, the following factors need to be considered:
In designing a pallet racking system, it's important to factor in the pallets' weight, dimensions, and whether they are 40" x 48", which is the standard size fitting most systems. This helps in determining appropriate rack depth and height for uprights. The palletized products' characteristics might also necessitate specific rack types depending on conditions like:
The number of Stock Keeping Units (SKUs) and pallet quantities per SKU in a warehouse heavily impact which pallet racking system to adopt. Selective pallet racking suits facilities with one pallet per SKU due to its flexibility and easy access. Facilities with multiple pallets per SKU might find higher-density systems like drive-in or push-back racking advantageous. For FIFO-oriented facilities with several pallets per SKU, pallet flow racking might be the best fit.
The expenses associated with racking systems are influenced by the environmental requirements of stored goods. Products may be kept under various climate conditions, such as:
The warehouse climate significantly affects product integrity, especially for perishables. Cold storage is crucial for foods to maintain low temperatures, while controlled conditions are vital for things like pharmaceuticals and cigars to ensure quality. Ambient conditions, where temperature isn't critical, limit expenses, whereas racking in cold environments often incurs higher costs because of:
Whether your racking system is being added to an existing facility or integrated into new construction affects cost, timeline, and space availability. Building structure considerations include:
The material handling equipment type and dimensions, like forklifts, lift trucks, or order pickers, determine aisle width and racking row count. Standard counterbalance forklifts usually require a 12-foot aisle, while man-up order pickers can function in tighter spaces. A warehouse layout with minimized aisles optimizes storage capacity.
Essential considerations when opting for storage racks include:
Analyze your company's product inventory, categorizing items based on aspects such as weight, density, delivery patterns, and lifespan. This evaluation aids in selecting the right type of rack or shelving. For instance, drive-in racks support bulk storage but may not serve high-selectivity items well. Selective pallet racks suit storing larger inventories of small-volume diverse products. Post identifying the right solution, further refine choices based on selectivity and density criteria.
Operating within budget constraints is crucial across all departments, including warehousing, emphasizing the significance of pallet rack costs. Costs generally cover storage, design, and installation aspects. While cheaper alternatives may seem attractive, maintaining quality is paramount. Experienced managers often choose competitive yet quality racks over cheap alternatives, proving more cost-effective over time by minimizing the need for replacements.
As your business evolves, so do your storage requirements. New products or changes in the product lineup can occur, necessitating flexible racking that adapts to these shifts. Choose storage systems that permit both minor and extensive adjustments. Racks like cantilever and selective types often provide this versatility.
Failure of pallet racks can result in serious warehouse accidents, with potential for severe injuries or significant product loss. To prevent such risks, it's crucial to select racks known for their durability and strength. Storage systems must be resilient over extended periods, with clear knowledge of each shelf's weight capacity to avoid collapse.
There are a wide variety of warehouse storage racks available, each engineered to optimize space, improve material handling efficiency, and enhance inventory management within logistics, e-commerce fulfillment centers, and manufacturing facilities. Understanding these racking systems and their best-fit applications helps organizations select industry-appropriate storage solutions that maximize productivity and meet diverse operational needs. The primary types of storage racks include:
Conventional pallet racks, commonly referred to as selective pallet racking systems, are the most popular storage rack solution in warehouses and distribution centers worldwide. This traditional pallet rack is an economical storage solution that offers direct access to every pallet—key for SKU management and order picking. These racks provide large storage capacity, are easy to install and adjust, and involve minimal equipment and capital expenses, making them ideal for small businesses as well as large-scale logistics operations. Conventional pallet racks allow for straightforward, selective access to products, facilitating efficient stock rotation, first-in/first-out (FIFO) inventory management, and streamlined warehouse workflow. They can be configured to fit any storage area, accommodate various product dimensions, and support different pallet weights and load capacities.
Each end frame of a pallet rack consists of two uprights, horizontal and diagonal bracings, footplates, bolts and nuts, and anchor bolts. The depth of the frame is determined by the size of the pallet; for example, a frame with a depth of 1100mm is typically used for a Europallet that measures 1200mm deep. Uprights can be customized to accommodate various loading requirements due to their diverse sections and thicknesses. To allow for beam height adjustments, uprights are equipped with symmetric hexagonal slots spaced at 75mm or 76.2mm intervals and are reversible.
Footplates are attached to the base of the uprights to provide support for the frames on the floor. Various types of footplates are available, depending on the load capacity and the model of the upright being used. One or two anchor bolts are employed to secure the footplates to the floor. Anchor bolts ensure that the racks are firmly anchored to the slab.
Footplates vary depending on the forces they must withstand and the properties of the slab. Each beam is equipped with two safety pins (optional: spring safety pins) to prevent dislodging during use. These pins offer extra protection for the sides of the rack base. Typically, safety pins are installed at the ends of frames and in the passages between them, where impacts are more likely. They help shield the racks from light impacts at ground level, minimizing localized damage to the vertical components. To ensure rack stability and worker safety, regular inspections, load limit adherence, and proper rack capacity calculation are recommended best practices.
Teardrop pallet racks, also known as rivet pallet racks or teardrop racking systems, feature a distinctive teardrop-shaped slot design that allows for tool-free, quick assembly. Unlike traditional pallet racks, they use rivets instead of hooks, making them especially easy to reconfigure for changing inventory needs. This type of racking system includes components such as uprights, beams, H bracing, D bracing, nuts, and bolts, supporting robustness and stability in high-traffic warehouse environments.
Teardrop racks are renowned for their versatility and compatibility across brands, which is especially beneficial for expanding or upgrading existing warehouse storage systems. Commonly used in various storage applications—including narrow aisle racks, drive-in racks, double deep racks, carton flow racks, and shuttle pallet racks—these systems are ideal for warehouses, distribution centers, and large retail outlets that require adaptability and scalability. Their modular design makes teardrop racks suitable for bulk storage, carpet storage, drum storage, tire storage, cable reel storage, racking-supported mezzanines, and many more industrial uses.
The rivet structure offers high shear resistance, preventing stretching or cracking during the manufacturing of beam connectors. The load on the upright holes in the rivet beam connector is applied vertically downward. The material is shaped into a hook and punched to create the stamped beam connector. This design is capable of meeting standard temperature requirements.
In a cold storage environment, the weight of the load must be carefully considered. Bolt connections between stamped beam connectors and upright holes result in bolt tension. The two beam connectors on a beam are identical, allowing the beam to be mounted upright or rotated 180 degrees vertically without altering the welding position; it simply needs to be turned 180 degrees. This flexibility accommodates either the bottom or upper beam needs. However, because stamped beam connectors are hung in one direction, customers needing both bottom and upper beams will require at least two types of beams. This requirement can complicate installation and make it less convenient.
Rivet beam connectors can be made from various materials based on specific requirements and are not constrained by workmanship. In cold storage environments, materials resistant to low temperatures can be used. The thickness of the material used for rivet beam connectors can be adjusted according to the load capacity requirements. However, the material limits the use of stamping beam connectors, as they are formed by stretching material into a hook shape with a punch. Therefore, only materials with strong tensile properties should be used. For example, SPHC material with a thickness of 3.5 mm or less is commonly employed.
Multi-tier pallet racks provide easy access to parts, components, and other items that are stored on a tall lattice of multiple levels that can be accessed via stairs. Highly effective for maximizing vertical storage in facilities with limited floor space, multi-tier pallet racking systems leverage unused height to expand storage capacity without altering the building’s basic structure. These high-density shelving systems are ideal for dense inventory stocking, small parts storage, industrial packing areas, and order fulfillment environments where direct access to individual SKUs is essential. Each level is accessible by stairs, which are unique to the design of a multi-tier pallet rack.
Aside from their multi-level design, multi-tier pallet racks vary according to their use. They can be additions to a mezzanine that has been added for additional office and workspace or be multiple shelving units. Their configuration is in accordance with the requirements of their users. Storage rack manufacturers work with their clients to develop forms of multi-tier pallet racks that match a client’s organizational structure. When custom-designed, these racks can efficiently house pick bins, conveyor systems, and automated storage retrieval systems (ASRS) to support modern, scalable warehouse operations.
Drive-in racks are designed for storing homogeneous products and can accommodate a large number of pallets for each SKU. This high-density storage method—often called a deep-lane racking solution—offers exceptional space utilization. It maximizes volume storage, similar to block stacking, while allowing forklifts to enter directly into lanes for pallet placement or retrieval. The system consists of a series of racking units that create internal loading aisles with pallet support rails, enabling Last-In/First-Out (LIFO) or First-In/First-Out (FIFO) inventory rotation, depending on configuration. Forklift trucks enter these inner aisles with their loads elevated above the level where they will be placed. Support rails are positioned on both sides of each loading aisle, allowing pallets to be stacked on different levels. Constructed from exceptionally durable materials, drive-in racks are suitable for storing fully laden pallets and are commonly found in cold storage warehouses, food processing plants, and high-turnover product environments.
Drive-in storage racks are an effective warehouse racking solution for maximizing storage space. They offer efficient use of warehouse footprint and generally support loading capacities ranging from 500 kg to 1500 kg per pallet. Adjustable rails enhance space efficiency and make the racks straightforward to assemble. Drive-in racks utilize FILO (First-In, Last-Out) or FIFO (First-In, First-Out) load management systems and are frequently chosen for storing large batches of uniform products where selectivity is not critical. Their cost-efficiency and density make them a top choice for frozen food, beverage, and bulk storage warehouses.
The number of SKUs that a drive-in system can accommodate is equal to the number of loading aisles available. The depth and height of these aisles will determine how many pallets can be stored. To minimize additional pallet handling, it is recommended to store merchandise with the same SKU in each loading aisle. The depth of each aisle is influenced by factors such as the number of pallets per SKU, available space, and the anticipated storage duration. The frames of drive-in racks feature slots every 75 mm to accommodate beams and supports. The overall depth of the frame is determined by the dimensions of the storage aisles, as well as the height, measurements, and weight of the pallets being stored.
Storage racks can feature either single or double arms. Single arms are mounted on the left or right side of the racks, while double arms are placed in the middle. For beam connections, raw steel is tested by an independent third-party agency to ensure quality and safety. These racks often include a three-hooker design, which supports high load capacities and effectively dissipates the beam load vertically down the front face of the upright. Each beam connector is equipped with five safety pins to enhance protection and prevent the beam from dislodging during use.
Support rails in drive-in racks are stamped and can be adjusted in length. These rails are designed without connectors to ensure consistent load distribution. Advantages of drive-in racks include their capacity for heavy-duty loading and the ability to consistently center pallet loads thanks to the rail profiles. Additionally, top beams and top bracings enhance the overall integrity and stability of the racking system.
The Pallet Shuttle Rack System is a compact, semi-automated storage solution where an electric motor-driven shuttle operates on rails within storage channels, eliminating the need for forklifts to access deep storage lanes. This automated racking system boosts warehouse efficiency and throughput by grouping items by channel—not merely by full lanes—enabling outstanding space optimization and rapid pallet movement. It enhances space utilization in depth, reduces the risk of forklift-related accidents and rack damage, streamlines operator movements, and brings greater modernization and flexibility to warehouse operations. The shuttle racking approach is particularly advantageous for organizations with high volumes of pallets per SKU and frequent loading and unloading cycles—especially in food, beverage, and cold storage environments where temperature control is critical.
In a Pallet Shuttle Rack System, the setup includes supporting racks, shuttle rails, and a shuttle cart. The shuttle cart, driven by an electric motor, rides on tracks and is operated via a hand-held remote control. A forklift is responsible for placing the shuttle cart into the designated lane. This system effectively optimizes space utilization and operational efficiency by reducing the need for forklifts to navigate within storage lanes.
Pallet shuttle racks offer significant flexibility, allowing each channel to accommodate different types of items. This system enhances productivity by improving the flow of incoming and outgoing items. With lower running, maintenance, and incident costs, pallet shuttle racks are highly cost-effective. They are also suitable for cold storage environments, making them ideal for warehouses with low temperature requirements, as they maximize storage capacity while reducing maneuvering time. When integrated with warehouse management software and barcoding/RFID tracking, these systems can significantly bolster inventory accuracy and real-time visibility, allowing for more efficient picking and replenishment.
Double deep pallet racks can accommodate two pallets deep in a single-entrance configuration or four pallets deep in a double-entry setup, allowing for efficient shipping of large single-SKU orders. By reducing the number of aisles and increasing storage capacity, double deep racks enhance storage density. This system is ideal for inventory profiles that require multiple pallets per SKU with moderate selectivity, although direct access is limited to the front pallets. Using this setup typically requires specialized lifting equipment with double-depth telescopic forks or deep reach trucks.
The design of a double deep pallet rack mirrors that of a standard selective pallet rack; while the layout differs, the components are the same. The transition from selective racking to double deep racks boosts storage density by altering the aisle-to-rack ratio. With effective stock rotation, around 50 percent of pallets are immediately accessible, and the system typically utilizes over 90% of available storage space. The reach truck can maneuver under the bottom beam since it is elevated from the ground. This approach is particularly effective for managing SKUs with multiple pallets. Double-deep racking is a preferred solution in manufacturing warehouses, retail distribution centers, and facilities seeking to balance density with access and picking speed.
The Very Narrow Aisle (VNA) rack system, as its name suggests, maximizes floor space and vertical height to achieve superior storage density. Designed for use in exceptionally narrow aisles (ranging from 1,500 to 2,000mm), this racking system significantly increases warehouse storage capacity by optimizing both square footage and vertical volume. Direct access to each pallet is preserved, and specialized articulated forklifts or turret trucks are required to operate safely and efficiently within VNA rack systems. These solutions are especially advantageous in high-volume environments where inventory accuracy, streamlined order picking, and high-speed throughput are central operational goals, such as in e-commerce fulfillment or third-party logistics (3PL) warehouses.
The forklift mast can move left or right as necessary, and forklifts with elevating operator cabins are also compatible with the system, enabling manual order picking. For narrow aisle racking systems to function effectively, it is crucial to have very flat floors, closely aligned racking, uniformly sized pallets, and precise stock locating systems, often coordinated with modern warehouse management software or automated guided vehicles (AGVs). Successful implementation requires careful design interaction among all system components and the use of floor guides in the aisles.
In narrow aisle racks, the extremely narrow aisles enhance storage density while allowing direct access to every stored pallet. Free-roaming trucks on the floor provide flexibility in multi-aisle environments. Specialized equipment is employed to create high-speed throughput, and meticulous material handling practices ensure a safe and damage-free operation. A robust, highly level floor is essential to support the weight of large loads. This VNA configuration is an integral component of space optimization and warehouse automation strategies seeking maximum cubic utilization.
Longspan shelving is designed for the manual storage of medium and small products, boxes, and pick bins. This highly adaptable racking system accommodates a broad range of unit loads—from cartons and totes to irregularly shaped inventory—and provides direct access to all items. Its basic framework can be easily customized with various accessories to meet specific organizational needs, including dividers, decking, and textile solutions. Longspan shelving is a leading choice for backrooms, storerooms, light-duty warehouses, retail storage, and pick modules where versatile, cost-effective shelving is required. With boltless assembly and modular shelf heights, it delivers flexible configuration for evolving storage requirements and is a core piece of any modern material handling strategy.
Carton Flow Rack Systems offer a high-density storage solution for cartons and small unit loads, optimizing both space and efficiency in case picking operations. Designed with a gentle gradient, these racks feature gravity-fed rollers or wheels that enable lightweight unit loads to glide smoothly from the back to the front of the rack, substantially speeding up order fulfillment and improving accuracy. Also known as flow-through racks or gravity flow racks, the system supports first-in/first-out (FIFO) inventory management and dynamic replenishment, making it an ideal solution for warehouses, distribution centers, and assembly lines handling fast-turnover stock and split case picking.
The pallet flow rack system operates on a similar principle to carton flow racks but on a larger scale, using conveyor wheel shelves that enable back-loaded pallets to move by gravity toward the front or pick face for automated or manual picking. This system is ideal for large-volume storage of perishable products, high-turnover items, and environments where FIFO management is crucial. Additionally, the push back rack system employs wheels within the rack structure, allowing palletized items to be stored by pushing them up a gently inclined ramp, maximizing density while granting multiple-pallet-deep storage. These gravity flow rack technologies reduce picking error, streamline restocking, and support high-throughput operations where space and labor optimization are top priorities.
This chapter will cover the applications and benefits of various storage racks, as well as their maintenance practices.
Rack systems are utilized across nearly every industry to create organized storage areas for products and materials. Examples include:
Warehouse racks often support heavy loads and, despite their robust design, can be prone to damage or failure. Regular inspection and maintenance are crucial to prevent potential accidents. This not only helps avoid damage to products but also ensures the safety of operators and prevents mishaps.
Industrial pallet rack maintenance, as outlined by the Rack Manufacturers Institute (RMI), might seem straightforward to an observer, but operators understand the complexity involved. The beam and column structure supporting stacked pallets may look simple, but even a slight additional bending load can jeopardize the entire system's stability. Therefore, regular inspection and maintenance of pallet racks are essential. It is crucial to perform these tasks correctly and professionally to ensure safety and structural integrity.
This article outlines the importance of inspecting and maintaining your pallet rack system and provides guidance on how to carry out these tasks effectively.
Pallet rack inspections are essential for protecting both materials and personnel and for ensuring compliance with OSHA regulations. Warehouse safety protocols encompass proper ventilation, adequate aisle space, clear flooring, prevention of slippery surfaces, and overall cleanliness. Therefore, industrial warehouses must be regularly inspected to maintain acceptable working conditions and safeguard the safety of operators.
The inspection of pallet racks is divided into two steps:
Maintaining pallet racks is crucial for extending their lifespan. These racks often endure uneven and excessive loads, making them susceptible to damage. To prevent or address damage, it's important to adhere to the RMI guidelines for assessing and repairing broken racks. Additionally, any rack repairs should be conducted under the supervision of a qualified expert, in accordance with RMI standards, to ensure safety and effectiveness.
The initial stage in pallet rack maintenance should be a thorough inspection. Once the inspection is completed, necessary repairs can be made to keep the warehouse rack system in good working order. For routine maintenance, ensure that any overloading situations are addressed by restocking commodities to avoid excessive stress on the racks. Pallets should be stacked evenly to minimize stress on the joints, and vertical stacking is often preferable to reduce beam bending stress compared to horizontal stacking. Additionally, replace any broken base plates and bolts to maintain long-term viability. It's crucial to keep aisles clear and enforce forklift speed limits to reduce the risk of accidents. Regular cleaning, rustproofing, and disinfection are also essential to maintain the system's condition and functionality.
Storage racks, also known as racking systems, are structures designed to store items and materials. They typically consist of at least two vertical frames, horizontal beams, and some form of decking, which may include bars, panels, or meshes. When selecting a storage racking system, it is important to consider the various types, their benefits and limitations, and their specific applications to make an informed decision.
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