This article takes an in-depth look at pallet racks.
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A pallet rack is an upright structure made of steel framing. Its beams and connectors are bolted, welded, or clipped together to form a pallet storage unit that stores inventory and equipment. In warehousing, pallet racks are an essential component that provides a safe, sturdy method for organizing and locating stored materials. The design and configuration of pallet racks make it possible to store any type of product, from food and clothing to heavy machinery and tools.
One of the reasons for the popularity of pallet racks is their versatility and ability to be reconfigured to meet the needs of any warehousing plan. Easy accessibility is a key factor for warehousing storage, which is the reason for the inclusion of pallet racks.
In a well-defined pallet racking system, pallets are stored in horizontal rows at multiple levels. The number of levels varies according to the pallets’ contents and the number of beam levels, which can vary from three up to six or seven. Pallet racks use otherwise wasted vertical space and provide an efficient, safe, and well-organized method for storing valuable inventory.
Pallet racking is available in a wide variety of styles, designs, and capacities, depending on the types of products being stored and the capacity of the building. The materials used to produce pallet racks determine their capacity and use. Most pallet racks are made of steel and can store several tons of products, merchandise, and materials.
The material handling business necessitates a wide selection of pallet racking types since every customer has different requirements and specifications. Depending on the application, there are several varieties, with basic features that all pallet racking must adhere to, which include forklift accessibility and components capable of supporting palletized materials.
Cantilever pallet racking can store pallets if designed properly. They are used to store longer products that cannot be stored on traditional racks. The key to cantilever racks is their weight capacity, which can vary to meet the needs of a particular product. They are made using upright columns, arms to secure the product, and horizontal braces between the storage bays.
In the selective pallet racking system, every pallet rack position is accessible from the aisle. This pallet system is the most common since it makes it possible to remove a pallet from the shelving without moving another pallet. Every item is visible for loading and unloading due to easy access. During inventory, there isn’t any need to remove an item from a pallet, which makes counting and calculations efficient.
Double deep pallet racking is for warehouses that have limited space and require quick handling. It is ideal for the first in, last out (FILO) system of warehousing. Double deep pallet racking is similar to selective racking with the exception that instead of there being one pallet on a shelf, there are two, with one in front of the other. The configuration is one rack placed tightly behind another such that the first pallet placed on the shelf is pushed back behind a second pallet placed on the shelf.
A special forklift is required to remove the second pallet since it is a full rack’s width back on the shelf. Double deep pallet racking decreases the number of aisles and makes greater use of the available space.
Push back pallet racking is ideal for density storage when there is limited space. The system is similar to a double deep system but includes far more than two pallets on a shelf. Pallets are loaded on carts or shelf trays that ride on rails set in the rack frame, which allows them to be easily pushed back when a pallet is loaded onto the shelf.
The system allows for multiple-sized pallets, up to six deep, to be placed on a shelf and is ideal for the last in and first out (LIFO) warehousing system.
Drive in drive through racking systems are designed for warehouses that have constantly shifting and moving inventory. Unlike a static system, with rows and aisles of racks, a drive-in racking system has a denser placement and makes efficient use of the available space.
In the drive in or drive through system, the forklift operates inside the racks, which do not have specified lanes between the rows. The forklift enters and exits through the same opening. The system is ideal for cold storage where there is only one entry point allowed.
Pallet flow racking, also known as gravity flow racking, uses roller tracks to form a gravity flow lane. The tracks are set at a decline that allows pallets to move easily from the rear of to the front of the rack. Brakes in the system control the rate at which the pallets move to ensure safe handling. A pallet flow racking system is rather extensive, capable of placing two to twenty pallets on the tracks of the rack.
Much like some of the other systems, the pallet flow racking system is designed for warehouses with limited space and is a FIFO system. It is ideal for products that are time sensitive or perishable.
Any number of add-ons can be included in a pallet racking system, including those specially designed to meet the specific needs of a product. Though pallet racks can store every form of product, certain products require racks designed to accommodate their unique features.
The few accessories listed above are only a small sampling of the accessories that pallet rack suppliers provide. Engineers and designers work with customers to develop customized accessories to meet the needs of special applications.
The identification of pallet racking is determined by how the horizontal beams attach to the vertical uprights. There are several forms of connections, which the manufacturer mainly determines. Though the purpose of the connection is to unite the two main structures of the pallet rack, this is completed to ensure that the pallet rack maintains a secure and firm support.
The pallet rack identification system describes the types of connections, including bolts, screws, clips, and fasteners.
The term teardrop refers to the shape of the holes in the racking’s upright frame. It is the most common and popular form of racking. The punched hole designs provide a secure fit between the horizontal beams and the uprights. The teardrop design assembles easily and quickly. A rivet shape with a flat head slides into the top of the teardrop. Once it is inserted, the shaft of the rivet slides down into the smaller portion of the teardrop so that the head of the rivet holds the horizontal support in place.
Structural pallet racking is used in areas that customarily have seismic activity. It is a more secure form of pallet racking, which uses nuts and bolts to connect between vertical and horizontal beams. The dimensions of structural racking are the same as all forms of pallet racking but are produced using heavier materials.
Hiline pallet racking, like structural racking, is used in areas where there is seismic activity and is made of heavier gauge steel. Unlike other brands, Hiline hole spacing is one inch from center to center. The horizontal and vertical beams are connected using clip pins or j-bolts. The color of its beams is orange with grey framing.
The slide and lock version of pallet racking connects the frame and beams using rectangular slots to easily slide hook-like brackets. Kotter pins may be added to enhance the security of the connection. The slide and lock style of pallet racking has become as common as the teardrop style. The lengths of the frames and beams in slide and lock pallet racking are standard and can be configured to fit any of the different types of racking.
Keystone pallet racking has symmetric channels with punched lips and has a single row of keystone slots in the front where the lugs on the beam clips fit. The frame has holes punched on both sides, offset from the keystones for safety clips to snap in.
A unique feature available as an option in Ridg-U-Rak slotted pallet racking is a pinch clip to lock the beams in place. This design does not use rivets; the hook material is formed to fit into slots in the column. The hook and slot design automatically locks the beam to the column. The slotted columns are enhanced with a 6-bend design section that adds stiffness to the return flanges, which improves section stability.
Speedrack pallet racking connections use a handle hook and J-hook safety pin to secure the beam and frame connection to prevent accidental beam detachment. The uprights for Speedrack pallet racking are closed rectangular or square tubing, which increases the stability and strength of the racking and gives it a higher weight capacity.
Sturdi-bilt pallet racking has a wedge lock clip system for holding the beams and uprights together. The beams have a clip that fits in a slot on the frame. The design makes sturdi-bilt pallet racking easy to assemble and configure. Originally, sturdi-bilt pallet racking did not have the extra clip for securing the wedge clips. It was added later as a safety precaution.
The T-bolt pallet racking style is the most popular racking style. It features T-bolts attached to the uprights using large bolts and is tightened and secured to provide proper capacity strength.
A tab at the end of the beam connector holds the beam in place as the T-bolt is attached at the front of the beam and is locked at 90o to hold it securely in place.
The ten pallet rack identifiers listed above are only a portion of the many styles, designs, configurations, and support systems used by pallet rack manufacturers. The list below includes other manufacturers, each of whom has its own designs and methods for pallet rack beams, frames, and connections.
As with all industrial equipment and materials, pallet racks require careful planning to support the materials they store and for the safety of personnel. Several key components are used in the construction of pallet racks, which are normally made of steel, galvanized steel, or an aluminum alloy. The construction of all pallet racks begins with the frame and horizontal beams.
A pallet rack system is a storage method for storing pallets loaded with materials that are aligned in rows on metal shelves. The multiple levels of beam elevations are accessible by forklifts and are designed to increase storage density.
The upright frame consists of vertical columns that rest on the floor and extend to the location of the top shelf. The columns of the frame have a series of holes cut into them to connect the cross beams. The height of the frame is the height of a loaded pallet plus the depth of the beam with a few inches or feet for clearance. These calculations determine the number of levels available on the pallet rack.
The cross beams serve two purposes: to connect the frame and serve as a support for the pallets. They have a connective bracket on each end that can securely attach the beam to the frame holes. Each beam level has two cross beams connected to the frame. One of which is at the front of the rack with the other at the back. In essence, the cross beams form the platform for the shelf and bear the weight of the pallets.
Concrete anchor bolts are used to anchor the feet of a pallet rack’s upright frame. For support, the upright frame of a pallet rack has feet welded to the bottom. Holes are drilled in the feet to place the anchor bolts to hold the pallet rack and frame securely in place. The purpose of the anchor bolts is to serve as an extra source of security and reinforcement.
The base plate or foot is welded to the bottom of the upright frame support and anchors the racking system. The size and width of the base plate are designed to distribute the weight of the rack and bear the weight of the column.
The base plate’s size depends on several factors, including soil-bearing capacity, concrete psi, the height of the rack, potential seismic activity, and the load capacity of the rack. They vary in thickness in accordance with the materials used to produce them. Wider base plates provide greater stability and minimize the chance of the rack tipping.
Crossbars are a method for increasing the safety of the pallet rack and assist in taking a portion of the load of the beams by distributing the weight. They are a way to ensure pallet rack security and prevent pallet rack failure. Crossbars can be horizontal or diagonal and are connected to the front and rear columns.
The design and construction of crossbars are to stabilize the rack’s frame and add support to the columns. A crucial aspect of pallet rack design is the need for the rack to remain in plumb. Crossbars and horizontal supports insurance that the rack maintains plumb regardless of its height.
Pallet rack decking is another means for increasing the safety of a pallet rack by providing support for pallets and a place for them to sit. The benefits of pallet rack decking include preventing items from falling from poorly stacked pallets and adding additional support. It also permits the use of lightweight pallets and ones that are oddly shaped.
The concept of pallet rack decking and its benefits are easy to understand. The selection of the type of decking can get a bit more complicated considering the many available decking varieties, including solid, wire mesh, wire, bars, wood, metal, and punched sheets.
The convenience and organizational benefits of pallet racking have made them an essential aspect of warehousing and storage engineering. Manufacturing and production facilities have large areas of space that go unused or underutilized due to positioning or the lack of the necessary tools. Pallet racking is an ideal solution to maximizing the use of underused or wasted space.
Efficiency is a guiding principle for modern manufacturing since it is a major component in saving time and increasing profits. Well-established organizations are very much aware of the need to take advantage of their assets, including having an economically designed storage operation.
A large portion of a warehouse is devoted to safe passage and access for forklifts. Storing materials spread across the floor makes them inaccessible and disorganized. By installing pallet racks, floor space can be maximized by utilizing the space below the ceiling. The wide varieties of pallet racking can be adjusted and configured to decrease the number of aisles and increase pallet storage space.
Pallet racking, such as push back and flow racking, provides a static and safe structure for loading pallets and storing bulk materials. High-density products can be conveniently stored and accessed without the need to change the warehouse structure.
Of the many aspects of conducting business, inventory control has been the most elusive. Regardless of the strides made in computerization and technology optimization, inventories invariably have to be adjusted every three to six months. Precision inventory control is an absolute necessity for increasing profits and providing efficient customer service.
A well-organized and precisely-planned pallet racking system is a major step in providing increased inventory control. The many add-ons and accessories available for pallet racking make it possible to plan an inventory system down to the smallest detail.
Every pallet racking system is designed, configured, engineered, and planned to exactly meet the needs of every individual warehouse. Though businesses may sell similar products, they may vary regarding organizing their storage space and picking patterns. The flexibility and adaptability of pallet racking make it possible to design a warehousing system that precisely fits the special needs of any warehousing plan.
Safety is paramount out of all the many reasons and benefits of having pallet racking. In manufacturing processes, disorganization and uncontrolled storage can lead to a wide array of disasters that can be harmful and costly. A well-secured pallet racking system provides a solid foundation for preventing harm to workers and materials.
Modern marketing and manufacturing have to be capable of responding appropriately to rapid changes in supply and demand. Products that were determined to be ineffectual or useless may suddenly become necessary. Pallet racking systems are an ideal answer to the constant shifts and changes in the demand for products and materials. Their open access and easy availability make it possible to shift product movement from one item to another quickly.
The key to a business’ success is the ability to provide on-time service to its customers. This requires careful planning, efficiency, and attention to detail. Having a pallet rack system makes any business capable of delivering smooth and cost-effective service, which leads to more opportunities and greater profits.
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