Warehouse Pallet Rack Systems & Components
A.I.T. Industrial Pallet Rack & Equipment sells new & used pallet racks, rack components, and pallet rack safety accessories. By utilizing
proper warehouse racking along with proper material handling solutions, your racking will provide organized warehouse space, easily accessible, reducing the clutter,
accomodating growth, and improving worker productivity.
Pallet rack systems are used in both industrial and warehouse-type facilities for materials that have been palletized or bundled and need
to be stored, transferred, or shipped. The use of pallet rack systems allows the facility to maximize the vertical warehousing space that would normally have gone unused. Palletized
products will now go multiple stories high utilizing all the vertical space available.
When we first start working with a new customer, we need to figure out what type of racking is needed. With a number of different warehouse rack designs available,
the most important step is to figure out exactly what type of racking will work best for the customer's purpose? Just a few of the specifics that dictate the customer's best racking choice include necessary
pallet flow, the direction of placement onto the rack, and the direction of removal off of the rack.
Setting Up Pallet Rack Systems
Pallet Racking for boxes
The desire from all forms of rack systems is to increase storage capacity by storing pallets and cartons off the ground using the warehouse's vertical space, rather than the usual horizontal storage. Going vertical with racking simplifies both the loading and unloading of pallets or cartons, maximizes your warehouse space, and improves your worker's efficiency.
Truck Tire Racks
Wire Mesh Decking For Racks
Well, designed Warehouse Racking Systems are usually deep, allowing for a large number of pallets or cartons to be stored at once. Necessary material
handling equipment includes a forklift to remove and replace loaded pallets from the racking. Open on all sides, pallet rack systems are a great choice when you must be able to access all the goods on
the rack without having to shift other items around.
Large Selective Pallet Racking Warehouse
Take Control Of All Your Warehouse Space
With over 25 years of providing our customers both excellent pricing and excellent racking recommendations. Industrial Pallet Rack & Equipment® Inc.
knows how frustrating it can be knowing your warehouse or industrial facility isn't organized as efficiently as it should be. We offer a large variety of new and used warehouse rack systems and components
for differing needs, warehouse material handling systems, and all the warehouse racking accessories to solve any obstacles you may run into. By installing a pallet rack system in your facility, you will create
a high-density storage system with plenty of capacity and easier access to stored loads. We offer everything from simple pallet rack systems to more innovative complex storage solutions, all at fair prices.
What Type of Pallet Rack Construction Is Best For My Warehouse?
There are two types of rack component construction, the difference being the weight it is designed to support. The first type is called roll-formed racks,
its strength is derived from the rolled (bent) shape. It uses less steel than the second type which is called structural steel bolt-together racking. Structural Bolt-together configuration is made of heavy
strength steel all the components are formed by casting molten steel, with reinforced channels. The structural bolt-together configuration is thicker and employs a stronger construction than what's found in
roll-formed pallet rack designs. Structural bolt-together pallet racks have 4 inch centered holes and use strong steel bolts as connectors. Strong and sturdy, more impact resistant than any roll-formed
Roll-formed racks are a less expensive option than the much stronger structural racks but are the perfect choice when the storage items are
not extremely heavy. Commonly seen holes in the roll-formed racks can be a keyhole shape, a teardrop shape, or a square shape. The shape of the hole is very important when trying to purchase more
equipment of the same type. We always suggest bringing a piece of the roll-formed racking along.
Roll Formed Racking
Structural Bolt-together configuration is made of heavy strength steel all the components are formed by casting molten steel, with
reinforced channels. The structural bolt-together configuration is thicker and employs a stronger construction than what's found in roll-formed pallet rack designs. Structural bolt-together
racks have 4 inch centered holes and use strong steel bolts as connectors. Strong and sturdy, more impact resistant than any roll-formed steel racking .
First In First Out and Last In First Out
There are two methods of setting up your racking system. There are flow rack systems designed to provide for a "FIRST IN, FIRST OUT" manner of storage. It is referred to as the "FIFO" method. In a FIFO design, loading is done from one side and products pulled off the racks from the other side. A good example of First In First Out material handling equipment is a refrigerated system for Gallon containers of milk. The milk is loaded from the higher end with the first to be loaded being the soonest to expire. Set up gravity feed to make product removal much easier, the milk is removed from the lower end where the closest to the expiration date will be the first to be removed.
Structural Bolt-Together Configuration
Then there are times when the storage shelving system doesn't require the complication of a "FIFO" system. You would rather have more storage available. Then the
warehouse pallet rack system can be designed to be a "LIFO". "Last In, First Out" system, which is a high-density storage system. Simply put, more products can be placed within the same amount of space.
First in First Out Rack System
The Elements of Simple Pallet Rack Systems
Pallet Rack Beams are the horizontal weight-bearing structures that connect the rack vertical uprights to each other. Vertical beams come in different lengths and sizes depending on the size of the pallet racking needed and the weight and dimensions of the items that will be stored on the racking. Manufactured in both roll-formed configuration and Structural Bolt-together configuration made of heavy strength steel with reinforced channels.
Warehouse rack beams are available in two different styles. You may purchase step beams or box beams. Box style beams allow
the use of optional over the top shelving, also called decking, or Step Style beams allow the use of drop-in support decking. Pallet rack beams can be adjusted to whatever height
is needed and can easily be readjusted to a different height level for future changing needs. Once the warehouse racks are all put together there is a multitude of rack accessories
and components that can customize the system to fit the individual needs of the storage area or the warehouse space.
Vertical Upright Frames are the vertical reinforced towers that are connected by horizontal beams to create 1 section of pallet rack bay.
The upright towers come in a variety of gauges to easily support the weight of the stored goods. Vertical uprights come in a variety of shapes and styles, and they range in height and width to suit the space available.
The strength of the vertical towers is critical to the structural integrity of the warehouse system. Besides selecting the correct vertical uprights to support the load, also ensure that the vertical uprights interlock
securely with the horizontal beams. If adding on to any existing racking already in place, make sure the verticals and horizontals all interlock securely.
When purchasing the horizontal beams and vertical upright towers, be sure to know your warehouse layout. One bay of racking consists of two vertical
upright towers connected by four pallet rack beams (unless more beam levels are needed). Each additional bay requires only one additional upright and four or more beams (depending on choice).
What Racking Accessories & Equipment Do I Need?
To be complete there are important racking accessories, safety accessories, and material handling equipment. Shop a wide selection of racking accessories
and equipment like aisle guards, anchor bolts, beam ties, collision warning devices, dividers, guard rails, pallet stoppers, pallet bumpers, pallet supports, row spacers, rack guards, rack ends, safety
netting, shelf dividers, upright protectors, wall brackets, wall spacers, wire decking, and more at low everyday prices at Industrial Pallet Rack & Equipment®. Rack components and accessories include
items that help strengthen the rack beams and increase the pallet racking systems efficiency.
A Forklift Truck gives your picker the needed assistance with loading and off-loading products or stored items from the warehouse racking systems.
To make sure you choose the right type of forklift, you should make a detailed list of your needs. This should include the layout of your warehouse, the type of loads you need to lift, the weight
of the load you want to lift, and the type of fuel you want to use. You should also consider the type of qualifications you'll need from your operator to operate the forklift.
Wire Mesh Decking are also called wire deck shelving. The wire deck provides a safe surface to support pallet loads. The mesh decking increases the safety and versatility of your racking by allowing you to store more than just standard pallets.
Upright Protector's help prevents damaging your verticle uprights. In a busy work, environment racking does get damaged due to the forklift's long forks, or
some other equipment ramming into the upright. Upright protectors prevent such scenarios. Purchase upright protectors and bolt to the floor to ensure safe warehouse conditions.
Fire Safe Mesh Decking
Make sure your racking is protected today with our durable, strong, quality upright protectors that will prevent
unnecessary damages, dents, destruction. Our protectors come both in metal and plastic.
Wall ties, Back-to-Back Ties, and Anchors to attach the racking to the wall or another rack for additional stability.
Safety Panels and Safety Straps to add to the sides or back of the racking, so that stored items don't fall off.
Spacers and Pallet Supports to add to the stability and integrity of the system.
Upright Protectors help prevent damaging your vertical uprights
The Type of Racking you Choose Depends On A Few Criteria
For More Information On Accessories & Equipment
- How tall the racking needs to be?
- What goods will be stored?
- What the floor plan will be?
- What type of inventory management system makes sense for your product and operation?
- What types of forklifts you currently use or forklifts you intend to switch to?
What are the Most Popular Pallet Racking Systems
There are a number of popular racking systems, each one having special situations where they are the better choice. The type of pallet loads, the direction of flow, the direction of placement, direction of removal, are just some of the factors to consider in choosing the type of racking. Rack systems help you stay organized within your warehouse and better manage your inventory. Choosing your racking, however, is not as simple as selecting a pallet rack brand and installing it. There several racking types that help meet your needs.
Push Back Racking
Picture shows an example of Push Back Racking
Push Back Racking is a system designed around the principle of organizing space by depth rather than width. This depth arrangement greatly reduces aisle space
and increases storage density. Push Back Racking is a LIFO (last in, first out) storage system that permits pallets to be stored up to 6 pallets deep on either side of an aisle, giving higher storage density than
other forms of racking. Each pallet is stored in the push-back system that rides on wheeled carts that fit onto isle rails. The rails are slightly angled toward the load/unload side of the rack to take advantage of
gravity, saving enormous amounts of energy for moving heavy pallets.
When removing a pallet from the front position the remaining pallets immediately stage themselves forward on wheeled carts so that the next available pallet can be accessed.
As a pallet is taken, the pallets move forward. When a forklift sets the pallet onto the cart, it drives the row forward and causes the pallet to bump the next pallet, causing the entire row of pallets to roll backward.
Similarly, when a forklift removes a pallet, with a push back racking system the pallet behind the removed pallet will roll forward to take its place. Push back racking gives you higher density storage than selective
racking while allowing you more selectivity with storing items than other types of racking, meaning you can store more SKUs. Many different cart designs can be designed to fit your needs.
For More Information On Push Back Racking
Selective Pallet Racking Systems
An example of a Selective Pallet Racking System
Selective Pallet Racking also referred to as just Selective Racking is the most popular and versatile form of racking. Selective pallet racking are some of the most
common and widely used racking systems, mainly because they are less expensive and easier to install than other, more specialized systems. Selective racking provides efficient use of space and with a forklift instant access to every
pallet in the facility. Because of the efficient use of floor space and minimal load and unload times. Selective Pallet Racking provides the user the most selectivity out of any of the warehouse racking systems. Since items on the warehouse
racks are only one deep, any item on the racking can be selected at any time. Selective Pallet Racking is also the most commonly used racking system, also the least expensive variety of racking available, based on cost-per-pallet
position. Recommended for many uses, consider for general warehousing, low turnover wholesale or retail, and lower quantity manufacturing.
For More Information On Selective Racking
Double Deep Racking
Picture shows an example of Double Deep Racking
Double Deep Pallet Racking provides access to two pallets instead of one, from the same side of the aisle, with one selective pallet rack placed behind the other pallet.
The advantage of Double Deep Racking is simply the ability to save space because of the need for fewer aisles to fit all the loads. Double Deep racking is best with a forklift that has installed telescopic forks or pantograph fork
attachment that can reach out far enough to take two pallets at a time.
Double Deep Racks consist of two rows of racking set back-to-back, hence the term “double deep.” The concept of double deep racking is similar to that of selective pallet racking,
but instead of two rows-per-aisle, there is now a total of four. This makes the double deep rack a first in, last out (FILO) system. The most obvious advantage of a double deep rack is its potential to increase storage density
and maximize warehouse space. The ability of double-deep racking to eliminate unneeded aisles means more warehouse space can be used for more storage. The increase in storage space is approximately forty percent which is significant.
The feature makes double deep racking among the most cost and space-efficient options available.
For More Information On Double Deep Racking
Pallet Flow Rack Systems
Pallet Flow Racks, Carton Flow Racks, Gravity Flow Racks. All three names are the same racking choice. A Carton Flow uses gravity to provide “gravity flow” to the racks. A (FIFO) first in, first out dynamic storage system, Pallet provides an efficient and ultra-dense storage system of palletized goods with fewer aisles. Pallet fully utilize available storage space and Pallet Flow Racks ensure the picking aisle has access to stocked pallets.
So the workings are simple. With a Carton Flow Rack System, pallets are placed on gravity rollers, (imagine a conventional pallet system, now equipped with roller channels mounted on a slight slope,) for gravity displacement of the load units. Pallets are loaded at the top end of a slightly inclined rack. Suitable for warehouses and manufacturing companies that need to guarantee a FIFO operation with maximum use of space, a high turnover of pallets, and minimal staff requirements. Pallets glide safely and effortlessly at a controlled rate to the front of the storage lane. This increases your storage capacity considerably. These heavy-duty systems are designed for years of trouble-free operations with rugged load-bearing wheels.
For More Information On Pallet Flow Rack Systems
Pallet, Carton, and Gravity Flow Racks
Cantilever Rack Systems
Cantilever Racking is used to store items that cannot easily be stored on pallets. Extremely dynamic, the perfect storage
fixture for steel bars, conduits, pipes, tubing, lumber, items too large for other industrial storage solutions. Cantilever Racking can be either single- or double-sided columns that
support vertically adjustable arms. They have also been called Lumber Racks or Pipe Racks. They come Single-Sided for against a wall, or Double-Sided depending on space and capacity.
Arms are bolted securely to the columns and can be angled to retain loads. A horizontal base helps stabilize the structure and supports the bottom load. Cantilever racks are made
specifically to accommodate your products and materials. Cantilever Racking can be utilized both inside and outside for any purpose. Another great advantage of cantilever racking
is that every arm is bolted to the upright and can be maneuvered to any level.
We can help you with ALL your cantilever racking
Cantilever Racks can also be good for shelving
Cantilever racking or Cantilever racks depending on how you say it is a multilevel medium for an extra heavy-duty storage solution with load-bearing arms anchored to
a strong steel column. The framework leaves the front of the racks unimpeded by structural elements for direct pick access to goods. Cantilever Racks have no front post or columns along
the aisle, therefore, optimizing space utilization and allowing immediate access to your inventory. To maximize the space being utilized, storage can be placed on every level including
the base. Cantilever Racks are made to accommodate long products, tend to lumber, and handles heavy, stressful loads to gain easier access with better-storing techniques to utilize your
workplace. Cantilever Racking comes in multiple forms which are Structural (H-Beam/I-Beam) and Rolled Form.
Cantilever pallet rack systems are forklift friendly, extremely dynamic, and can help anyone stocking lengthy, heavy items. Cantilever Racking
can be utilized both inside and outside for any purpose. Another great advantage of cantilever racking is that every arm is bolted to the upright and can be maneuvered to any level.
Single-Sided Cantilever Rack is primarily purchased when placing the racking against a wall to stock products and materials.
Double-Sided Cantilever Rack are placed in parts of the warehouse where both sides of the racking are accessible. Double-Sided
have arms on both sides with all the arms sharing the same uprights and supports.
We provide easy guidance to help you select which cantilever racking system is best for you. We know the industry inside-out and are prepared to give you some
of the best advice on warehouse storage systems. We help design, specify and coordinate installation projects with our fast and easy service to get you the cantilever racking you need
For More Information On Cantilever Racking Options
Light Duty Cantilever Rack
Medium Duty Cantilever Rackss
Heavy Duty Cantilever Rack
Drive-in racking's a high-density storage system used in warehouses to store pallets on a first in/last out (FILO) basis. Pallets are loaded and retrieved from the front side of the rack
and forklift trucks drive directly into the rack's bays to get to the stored product. On a Drive-In Pallet System, The last pallet loaded becomes the first pallet accessible, creating a more dense and uniform load in a confined storage area.
Drive-through racking work similarly, except in this case the pallets are stored on a first-in/first-out (FIFO) basis. To accomplish this the pallets are loaded on one side of the rack and the forklift
retrieves product from the opposite side.
Drive-In Racking is also called Drive-Through Racking. Traditional racking is a great storage solution for a wide variety of warehouses and distribution centers. However, if you have a lot of inventory that shifts regularly, drive-in or drive-through racking is a high-density storage space-saving solution you may want to seriously consider. While traditional static rack storage allows for many rows of racking with aisles between the individual rows, drive-in and drive-through racking allows for a much denser arrangement of your stored product. Both drive-in and drive-through rack systems allow more efficient use of available space than traditional multi-aisle selective racking. The key difference between these racks and selective racks is that the forklift truck operates inside the rack itself and there are no specified lanes between the rows. The forklifts enter into the individual bays of the rack and the bays themselves can be as long or as short as needed.
Drive-in racking decrease's the total amount of storage space needed and the retrieval time, at the same time increasing both efficiency and productivity among workers.
Not only do they benefit your operations, but they can also decrease your bottom line by giving you more storage room per dollar spent on racking. Because these racks create a more uniform load in a confined storage
area, your forklift operators working in the system need to become more skillful drivers. In addition to these benefits, consider this – drive-in & drive-through systems are very energy efficient. Since the product
is so densely loaded in this type of system, there is less air to be heated or cooled between your pallets and your forklifts don't need to drive as far to pick or place loads, thereby using less fuel.
Drive-In & Drive-Through Racking is very energy efficient
Drive in and drive through rack systems decrease storage space
Mobile Rack System
Mobile Rack Systems are a highly compact high-density rack system, that is designed to maximize the use of warehouse storage space. Mobile racking is ideal
for warehouses or any location that requires a compact storage solution for heavier items. Mobile Racking eliminates idle aisles by mounting mobile carriages to all racking. With mobile racking, it reduces
the needed storage area to 1/2 of what you normally used, or another way of looking at it, mobile shelving will DOUBLE the amount of storage space you have.
Mobile Rack Systems move on strong wheels riding on a track called a mobile carriage. The mobile carriages are extremely strong with load capacities from 7,000 to over 30,000 lbs.
each shelf in the racking block is mounted to a mobile carriage either in or on the floor. The ability to anchor the mobile carriages to existing concrete floors makes it a very cost-effective solution for increasing capacity
in any space, without the need for renovation or expansion. All mobile pallet rack units are installed over guided bases that slide laterally, eliminating the need for multiple fixed aisles. They also are fitted with a host of
safety and security features.
With mobile shelving, the rack system aisles open up only when the operator requests access. Otherwise, they are closed. Most of the time the moving aisles are operated by electric motors,
the Mobile Racks are controlled directly using operator controls on the racks or based remotely. As a matter of fact, the entire system can easily be integrated into an existing warehouse management system.
For More Information On Mobile Racks
There Are Numerous Applications for a Mobile Racking Systems
Pallet Rack Safety
Pallet rack safety often gets overlooked by both the forklift operators and other warehouse support. Pallet loads are lifting off and placing
on rack systems by forklift operators that are all day maneuvering to clear both stationary and moving obstacles.
Warehouse pallet racking must be built with safety in mind. Structurally strong and stable. Warehouse rack aisles need to be wide enough apart for forklift
operators to safely turn into and out of the aisles without having to negotiate any tight turns. Mandated by OSHA for warehouse safety, all forklift operators must go through forklift operator training.
Even with the proper operator training, a warehouse rack failure may still occur from improper or risky forklift operation. Accidental contact with one of the pallet rack vertical uprights is a common
component of total rack failure. Of course, to minimize the risk of any disasters follow all of the recommended racking recommendations
Use Steel Guardrails and Protective Posts
Reduce Risk With Steel Protection
There is always the risk of even the best-trained forklift operator bumping into the corner of a racking post. Reduce the risk of disaster
by correct placement of heavy-duty steel guardrails and high-visibility yellow bollard protective posts. Install heavy-duty column protectors to take the impact of collisions before they reach the racking. Column
protectors may not be able to completely protect the racks from collisions, but they can take the initial impact and reduce the damage caused by collisions..
For added protection, install end-of-aisle guards. These guards will help protect from forklift trucks that are turning corners or backing up without full visibility.
Floor markers and reflective markers also help forklift trucks and other material handling operators to know their limits and the areas where they should stay. Finally, warehouse pallet racking systems are often
reinforced by doubling up on the size of vertical supports for extra strength where it matters most.
Anchor All Storage Racking Down To The Warehouse Floor
You Must Anchor Racking To The Floor. Unfortunately, we see far too many freestanding pallet rack units in our travels. For safety's sake, a running
warehouse needs all its racking to be very stable. Anchor to the floor with 3-1/2" long by 1/2" diameter concrete rack bolts.
Use Pallet Rack Netting and Wire Mesh Rack Guards
Don't Let Items Fall Off the Back Of The Rack.
When forklift operators are loading items onto the front of the rack, they should not need to consider the possibility of items falling off of the back of the rack.
Barriers need to be in place that will prevent items from falling, potentially causing injury to a passer-by. Safety Netting or Wire Rack Guards are what's used and installed on all pallet rack backs and pallet
rack sides facing areas in the warehouse where warehouse workers or passer-by's walk.
Adhere to Maximum Labeled Weight Capacities
The first step is to post all weight capacities. Both the horizontal beams and vertical uprights must have their weight capacities posted clearly and should never be exceeded
for any reason. Forklift operators loading storage racks beyond the level the racking is designed to handle will weaken and compromise the racking structure, eventually leading to failure. OSHA and ANSI (the American National
Standards Institute) recommend all storage racks display a data plaque, plate, or label with clear and detailed information about the rack's load capacity.
Proper Pallet Rack System Loading Techniques
Operators of forklifts must have enough horizontal and vertical space in every loading bay to safely store and receive products. Pallets must be loaded squarely onto the racks to
maintain the stability of both the load and the stability of the rack itself. Loads placed onto the racking must be supported fully by the support beams and cannot be placed onto just the wire decking. Having the proper dispersion
of weight will also be much easier on the entire system, not putting stress on one area more than another.
Conduct Storage Rack Inspections On A Regular Basis
We recommend monthly inspection of your warehouse storage rack system. Stand at each aisle end and look carefully for any sign of racks that are leaning,
sagging, or experiencing any sign of strain. Walk down each aisle looking for any signs of damage (dents, twisted supports, loose or broken footings, etc.) We also highly recommend having a third-party
racking inspection company conduct a more in-depth inspection a minimum of twice a year.
If We Can Help You With Anything, Give Us a Call
Leaning Pallet Racks Could Be a Very Dangerous Situation |
Maximum inclinations (degree of lean), must be kept to the minimum for both empty and fully loaded racks. The degree of lean never should be allowed to exceed spec's.
Finding Bent Beams & Bent Verticle Upright |
Finding slightly bent beams and verticle uprights can be a wake up call to potential danger. Bent Horizontal Beams and verticle uprights must be
replaced if bent at all.
Never Exceed Pallet Rack Maximum Weight |
The weight of the load must never exceed the pallet rack max weight capacity. One misplaced pallet location could take the load beyond weight capacity./p>
Copyright © 2021 American Investments Technologies LLC – dba Industrial Pallet Rack & Equipment® All rights reserved
Using any of the photographs on this website for commercial use is prohibited without permission from Industrial Pallet Rack® Inc.
In Florida Serving:Fort Lauderdale, Miami, West Palm Beach, Tampa, St. Petersburg, Clearwater, Bradenton,
Sarasota, Naples, Ft. Meyers, Ocala, Lakeland, Plant City, Orlando, Jacksonville, Tallahassee, Pensacola