Storage rack manufacturer information and descriptions of their products.
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This chapter explains what storage racks are, how they function, and the key factors to evaluate when designing or selecting an effective storage racking system.
Storage racks, also known as racking systems, are engineered structures used to store materials, products, and palletized goods in warehouses, distribution centers, and industrial facilities. A typical storage rack consists of two or more vertical uprights, horizontal load beams, and optional decking components such as wire mesh, steel panels, bars, or open supports, depending on the application.
Several important factors must be evaluated when designing or selecting a storage rack system to ensure safety, efficiency, and optimal space utilization.
Pallet dimensions, weight capacity, and load characteristics play a critical role in pallet rack design. The most common pallet size is 40 inches by 48 inches, which fits most standard racking systems. Knowing pallet size and weight helps determine appropriate rack depth, upright height, beam capacity, and load spacing. Additional product considerations may influence rack selection, including:
The number of stock keeping units (SKUs) and the quantity of pallets per SKU strongly influence the choice of pallet racking system. Selective pallet racking is ideal for operations with many SKUs and single pallets per item due to its high accessibility and flexibility. Warehouses storing multiple pallets per SKU may benefit from higher-density systems such as drive-in, push-back, or pallet flow racking. Facilities that prioritize first-in, first-out (FIFO) inventory rotation often rely on pallet flow racks for efficient product movement.
Environmental conditions within a warehouse significantly affect both rack selection and overall system cost. Storage racks may be installed in environments such as:
Climate requirements directly impact product integrity, especially for perishable foods, pharmaceuticals, and regulated goods. Cold storage installations typically involve higher costs due to longer installation times, specialized labor requirements, and the high cost of refrigerated space. Regulatory considerations, such as FDA requirements for food storage—often mandating a minimum clearance of 12 inches from the floor—must also be incorporated into rack design.
The physical characteristics of the building influence rack layout, installation complexity, and available storage capacity. Key structural factors include:
The type and dimensions of material handling equipment, such as forklifts, reach trucks, and order pickers, determine aisle width and racking density. Standard counterbalance forklifts typically require aisle widths of approximately 12 feet, while narrow-aisle equipment and man-up order pickers can operate in tighter spaces. Designing a layout that minimizes aisle width while maintaining safe equipment operation maximizes overall storage capacity.
Choosing the right storage rack system requires balancing operational needs, safety, flexibility, and cost.
Begin by evaluating the characteristics of your inventory, including product weight, size, density, turnover rate, and storage lifespan. This assessment helps determine whether pallet racks, shelving, or specialty racks are most appropriate. For example, drive-in racks support high-density bulk storage but limit selectivity, while selective pallet racks provide easy access for diverse product inventories. Once the general rack type is selected, further refinements can be made based on selectivity and storage density requirements.
Cost considerations are critical when investing in warehouse racking systems. Pricing typically includes design, materials, installation, and sometimes permitting or compliance requirements. While lower-cost rack options may be appealing, long-term durability and safety are essential. Higher-quality storage racks often deliver better value over time by reducing maintenance, minimizing damage, and lowering replacement costs.
As inventory profiles and business operations change, storage systems must adapt. Flexible racking solutions allow for reconfiguration, expansion, or modification without requiring complete replacement. Systems such as selective pallet racks and cantilever racks are commonly chosen for their ability to accommodate evolving storage needs.
Pallet rack failures can lead to serious workplace injuries, equipment damage, and inventory loss. Selecting racks engineered for strength, load capacity, and long-term durability is essential. Clearly defined weight ratings, proper installation, and routine inspections help ensure safe operation and extend the service life of storage rack systems.
Key factors include pallet size and type, number of pallets and SKUs, warehouse conditions, building structure, material handling equipment, storage needs, budget, rack flexibility, and the strength and longevity of the system.
Storage racks maximize the usable volume by organizing products vertically and horizontally, enabling higher density storage, better workflow, efficient stock rotation, and improved access to inventory, all of which streamline warehouse operations.
Drive-in racks and pallet shuttle racks are frequently used in cold storage and food facilities. These systems maximize storage density, meet FDA clearance requirements, and suit temperature-controlled operations for perishable inventory.
Regular inspections for structural damage, load limit compliance, even pallet stacking, replacing damaged components, keeping aisles clear, enforcing forklift speed limits, and routine cleaning and rustproofing are crucial for safe and long-lasting rack use.
Storage racks are widely used in aerospace, automotive, food and beverage, chemicals, e-commerce, distribution, hospitals, pharmaceuticals, manufacturing, construction, and retail warehousing, among many other sectors.
Local conditions such as ceiling height, dock door layout, floor space, and column positions affect rack configuration, cost, and installation. These factors must be aligned with the chosen racking system and facility workflow requirements.
Warehouse storage racks are available in a wide range of designs, each engineered to improve space utilization, material handling efficiency, and inventory control in warehouses, distribution centers, e-commerce fulfillment facilities, and manufacturing operations. Understanding the different types of storage racks and their ideal applications helps businesses select racking systems that support productivity, safety, and scalable growth. The most common types of storage racks include the following.
Conventional pallet racks, often called selective pallet racking systems, are the most widely used warehouse storage solution worldwide. These pallet racks provide direct access to every pallet, making them ideal for operations that manage a high number of SKUs and require efficient order picking. Conventional pallet racking is cost-effective, easy to install, and simple to reconfigure, making it suitable for small warehouses as well as large logistics and distribution centers. This system supports FIFO inventory rotation, flexible product placement, and efficient warehouse workflows while accommodating varying pallet sizes, weights, and load capacities.
A standard pallet rack frame consists of two vertical uprights connected by horizontal and diagonal bracing, along with footplates, bolts, and anchor hardware. Frame depth is determined by pallet size; for example, a frame depth of 1100 mm is commonly used for a 1200 mm deep Europallet. Uprights are manufactured in various thicknesses and profiles to meet different load requirements and feature evenly spaced slots—typically at 75 mm or 76.2 mm intervals—allowing precise beam height adjustment and system reversibility.
Footplates at the base of each upright distribute weight to the floor and are selected based on load capacity and slab conditions. One or more anchor bolts secure each footplate to the concrete slab, ensuring rack stability and resistance to impact forces. Proper anchoring is essential for maintaining structural integrity and workplace safety.
Beam safety pins or locking devices are used to prevent accidental beam displacement during forklift operations. These protective features are especially important in high-traffic areas where impacts are more likely. Regular rack inspections, strict adherence to load limits, and accurate capacity calculations are critical best practices for maintaining long-term rack performance and employee safety.
Teardrop pallet racks, also known as rivet pallet racks, are characterized by their teardrop-shaped slots that allow beams to be installed and adjusted without tools. This design enables fast assembly and easy reconfiguration, making teardrop racking a popular choice for dynamic warehouse environments. The system includes uprights, beams, horizontal and diagonal bracing, and fasteners that provide strength and stability in demanding applications.
Teardrop pallet racks are highly versatile and widely compatible across manufacturers, which simplifies expansion or system modification. They are commonly used in selective racking, narrow aisle systems, drive-in racks, double-deep racks, carton flow racks, shuttle racking systems, and racking-supported mezzanines. Their modular design supports a broad range of storage needs, including bulk goods, tires, drums, cable reels, carpets, and industrial materials.
The riveted beam connector design provides strong shear resistance and directs load forces vertically into the upright. The stamped connectors are engineered to meet standard temperature and load requirements, offering reliable performance in both ambient and cold storage environments.
In cold storage applications, material selection and load calculations are especially important. Rivet beam connectors can be manufactured from temperature-resistant steel to maintain strength under extreme conditions. Beam connectors are identical on both ends, allowing beams to be installed in either orientation. However, because connectors engage in one direction, different beam types may be required for upper and lower levels, which can add complexity during installation.
Connector thickness and material grade are selected based on required load capacity. Because stamped connectors rely on material tensile strength, only suitable steel grades—such as SPHC with controlled thickness—are used to ensure durability and long-term reliability.
Multi-tier pallet racks maximize vertical warehouse space by creating multiple storage levels accessed by stairways. These systems are ideal for facilities with limited floor space and high ceilings, allowing businesses to significantly expand storage capacity without increasing building footprint. Multi-tier racking is commonly used for small parts storage, order fulfillment, packing operations, and high-density inventory environments where direct SKU access is required.
Multi-tier pallet racks can be standalone shelving systems or integrated into mezzanine structures that combine storage with office or workspace areas. Each system is custom-designed to meet operational requirements, with options to incorporate pick bins, conveyors, and automated storage and retrieval systems (ASRS). This flexibility makes multi-tier racking a valuable solution for scalable and efficient warehouse layouts.
Drive-in racks are high-density storage systems designed for storing large quantities of uniform products. Forklifts enter the rack structure to place and retrieve pallets from deep storage lanes, making this system ideal for bulk storage where selectivity is less critical. Drive-in racking maximizes cubic storage space and supports either LIFO or FIFO inventory management, depending on configuration.
These racks are constructed with pallet support rails mounted along each lane and are capable of handling heavy pallet loads, typically ranging from 500 kg to 1500 kg per pallet. Drive-in racks are widely used in cold storage warehouses, food and beverage facilities, and manufacturing operations that handle large volumes of identical SKUs.
The number of SKUs stored in a drive-in system corresponds to the number of available lanes. Lane depth and height determine total pallet capacity and are influenced by pallet size, load weight, and storage duration. Frames feature regularly spaced slots for flexible placement of beams and rails, while single or double support arms are used based on rack layout.
Drive-in racks often incorporate multi-hook beam connectors and multiple safety pins to prevent accidental dislodging. Adjustable stamped support rails help center pallets and distribute loads evenly. Top beams and bracing further enhance rack stability, making drive-in systems suitable for demanding, high-load environments.
Pallet shuttle rack systems are semi-automated, high-density storage solutions that use a motorized shuttle to move pallets within deep storage lanes. Forklifts place the shuttle into the lane, eliminating the need for forklifts to enter the racking system. This design improves safety, increases throughput, and maximizes storage density, particularly for operations with high pallet volumes per SKU.
The system consists of rack frames, shuttle rails, and a battery-powered shuttle controlled by a handheld remote. By reducing forklift travel time and minimizing rack impacts, pallet shuttle systems lower operating costs and increase efficiency. They are especially effective in cold storage environments and facilities requiring fast loading and unloading cycles.
Pallet shuttle racks support flexible SKU management by allowing different products to be stored in separate channels. When integrated with warehouse management systems and barcode or RFID tracking, these systems enhance inventory accuracy, visibility, and operational control.
Double deep pallet racks store pallets two positions deep on each side of an aisle, reducing aisle count and increasing storage density. This system is ideal for warehouses that store multiple pallets per SKU and can tolerate reduced selectivity. Specialized reach trucks or forklifts with telescoping forks are required to access rear pallets.
Structurally similar to selective pallet racks, double deep systems increase space utilization by modifying aisle-to-rack ratios. Approximately half of stored pallets are directly accessible, while overall storage utilization often exceeds 90%. This racking solution is commonly used in manufacturing warehouses, retail distribution centers, and facilities seeking a balance between density and access.
Very Narrow Aisle (VNA) rack systems are designed to maximize both floor space and vertical height by minimizing aisle width, typically between 1,500 and 2,000 mm. These systems provide direct access to every pallet while significantly increasing storage capacity. VNA racks require specialized equipment such as turret trucks or articulated forklifts and are commonly used in high-volume distribution centers and e-commerce fulfillment operations.
Successful VNA installations depend on flat, level floors, precise rack alignment, consistent pallet dimensions, and advanced inventory management systems. Floor guidance systems and automation technologies are often used to support safe and efficient operation.
By combining high-density storage with fast order picking, very narrow aisle racking plays a critical role in warehouse optimization strategies focused on maximizing cubic utilization and throughput.
Longspan shelving is designed for manual storage of cartons, bins, and medium-weight items. This adaptable shelving system provides direct access to all stored products and supports a wide range of storage configurations. Accessories such as dividers, decking, and shelf liners can be added to accommodate specific inventory needs.
Commonly used in storerooms, retail backrooms, light-duty warehouses, and picking areas, longspan shelving features boltless assembly and adjustable shelf heights. Its flexibility and cost-effectiveness make it an essential component of modern material handling systems.
Carton flow rack systems are gravity-fed storage solutions designed for fast and efficient case picking. Featuring inclined roller tracks, cartons move automatically from the loading side to the picking side, supporting FIFO inventory rotation and reducing picking time. These systems are ideal for high-throughput warehouses, assembly lines, and distribution centers handling split-case orders.
Pallet flow racks operate on the same gravity principle but are designed for palletized loads, while push-back racks use inclined carts to store multiple pallets deep. Together, these gravity-based systems improve storage density, reduce labor requirements, and support efficient replenishment in fast-moving operations.
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, commonly referred to as warehouse racking systems, are engineered structures designed to organize, store, and support materials efficiently within warehouses, distribution centers, and industrial facilities. These systems typically include vertical frames, horizontal beams, and optional decking such as bars, panels, or wire mesh to accommodate different load types. Selecting the right storage racking system requires evaluating rack styles, load capacities, space constraints, and operational needs to ensure safe storage, efficient material handling, and long-term warehouse performance.
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