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Pallet Rack Design


Two persons discussing pallet rack design

Importance of Good Pallet Rack Layout Design

Designing an efficient warehouse pallet rack system can be complex, with many factors to consider. It's essential to assess your business’s needs and physical constraints before investing in a pallet rack system. A well-designed storage rack system should allow for easy placement and removal of inventory without causing damage, while maximizing the available storage space.

Increase Storage and Available Space

Every pallet rack system should optimize the storage capacity of your warehouse. These systems not only enhance your inventory management but also multiply the usable space in your warehouse or factory. Businesses that have implemented pallet rack systems often see a significant improvement in product turnaround and can maintain a first-in, first-out (FIFO) system efficiently.

Warehouse Organization is in the Design

A well-designed pallet rack system can be as valuable, if not more, than investing in inventory management software. Thoughtful design encourages discipline in organizing products, optimizing space, and reducing labor costs. A well-planned system ensures that products are stored in a manner that maximizes efficiency.

Different Types of Pallet Racking

There are various types of pallet racking systems available, including selective rack, cantilever pallet rack, double deep rack, drive-in and drive-thru rack, push-back rack, pallet flow rack, and carton flow rack. These racking systems are designed to support heavy materials while requiring minimal maintenance. They are known to increase storage density and make the transportation of goods more efficient, which is why many industries now rely on pallet racking for warehouse storage.

Cantilever pallet racks are ideal for storing long items that don’t fit in a single pallet space. These racks have adjustable arms to accommodate long products like pipes or lumber.

Structural pallet racks, made from reinforced steel, offer several advantages over other types. The thicker steel columns and channels provide greater strength, which allows them to withstand impacts from forklifts. Structural racking systems also use positive mechanical connections like bolts or welds, offering greater durability.

Push-back racking is a gravity-driven system that uses wheeled carts. When a pallet is removed from the front, the pallet behind it automatically moves forward. These systems can be customized to increase storage capacity or provide a level surface for swing reach turret trucks.

Identify the Pallet Rack Style

To help you identify the type of racking in your warehouse, reference the images provided. By examining how the beams connect to the frame, you’ll be able to identify the style of pallet rack and order matching components from the manufacturer.

Pallet Rack Construction Basics

Pallet rack beams are typically adjustable in 2-inch increments and come in three main types: Structural, Roll Formed, and Hybrid (which combines structural frames with roll-formed beams). Pallet rack systems are designed to store materials on skids (pallets), arranged in horizontal rows and stacked in multiple levels.

The most cost-effective finish for pallet racks is powder coating, which extends the life of the racks by reducing maintenance needs. Powder coating provides 60% greater resistance to solvents, 74% better protection against salt sprays, and 94% higher impact strength compared to other finishes, ensuring your racks remain durable and long-lasting.

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