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Pallet Racking

Pallet Racking is a material handling storage aid system designed to store materials on pallets. Although there are many varieties of pallet racking, all types allow for the storage of palletized materials in horizontal rows with multiple levels. All types of pallet racking create some level of increase storage density with the least dense being the least expensive and cost increasing with storage density. Pallet Racking is an essential and ubiquitous element in most modern warehouses, manufacturing facilities, retail centers, and other storage and distribution facilities. Adjustable Pallet Racking systems offer accessibility to all palletized products at all times. Such accessibility is important if the stock is rapidly depleted and restocked (called quick turnover).

Adjustable Pallet Racking Systems (APR)

Adjustable pallet racking (APR) is the most common pallet racking system in use today. Adjustable pallet racking typically comes in one of two configurations: a Welded Framed configuration, and a structural bolt-together configuration. Both systems adopt a clip-in horizontal beam system for installation and adjustment purposes.

Wide Aisle is the use of Adjustable Pallet Racking in a configuration with an aisle width of typically 2800mm. For use with a Reach type Fork-lift truck this system is very common where speed of pick is essential.

Very Narrow Aisle (VNA) is the use of Adjustable Pallet Racking in a tighter configuration to provide maximum space utilization within a storage facility. These systems typically operate in conjunction with wire-guided or rail-guided fork lift truck systems. A wire-guided system consists of a wire embedded in the concrete floor that provides tracking for the fork lift truck. A rail-guided system consists of angle iron bolted to the floor down the length of each row. A Very Narrow Aisle pallet rack system is commonly used in distribution centre applications, as well as in retail store inventory rooms, cold storage applications, wholesale stores, etc.

More information On Adjustable Pallet Racking Systems....

Common components of Adjustable Pallet Racking include the following:

Load Beams, commonly box beams formed structural C shapes welded together to form a box with connecting angle at either end. Beams vary in size and design depending on load requirements. In the UK market Beams or generally 2700mm long to provide storage and clearance for two 1200mm wide pallets or three 800mm wide pallets.

Upright Frames vary in size and design depending on load requirements, and styles. The most common upright column is produced by roll forming flat coil stock steel into a modified "C" shape with returns. Holes or slots are punched during manufacturing up and down the upright column at standard intervals so that the load beams can be mounted into the upright columns.

Diagonal and Horizontal frame Bracers usually bolted between two upright columns to form upright frames. The Bracers may also be welded to the uprights on some types of system.

Pallet Supports are roll formed channels that are placed front to back between the load beams to support pallets.

Wire Decking is commonly used as a safety measure on pallet rack to prevent pallets or the products stored on them from falling through the rack structure. Wire mesh decking comes in various thicknesses and mesh dimensions. Wire mesh construction also allows for easy identification of shelf contents and prevents dirt and other debris from accumulating on the shelves because of the holes in the mesh. Most wire mesh decking has U-shaped channel supports, also known as struts, to support the load. With this waterfall decking, the wire mesh extends across the top and down the front of the beam to provide more support, and is more desirable in the marketplace. Reverse waterfall decking can provide containment of a loose product to prevent the product from falling behind the rack system. Lay-in decking rests inside the step of the beam, and wire mesh does not waterfall over the beam. Some types of decking are manufactured with solid metal instead of wire mesh. Even though the solid decking provides a greater distributed weight capacity, it is discouraged by fire inspectors because sprinkler systems cannot spray through the shelves to levels below.

Foot plates are at the base of uprights and serve as anchors to give the rack more stability: anchor bolts are inserted through the footplate’s holes to attach the column to the concrete floor. Footplates are made of thicker steel and in some geographic locations; they must be of a certain size and seismic rating. Footpads increase the pallet rack’s overall stability and weight-bearing capacity.

Shims are used when the uprights are resting on uneven floors; the shims, equal in size to the base of the uprights, are installed beneath the uprights to level the rack.

Row spacers are sometimes used if uprights are arranged in back-to-back rows; the spacers are mounted between adjacent columns to ensure that the rows are kept straight and to give the pallet racks even more strength and steadiness.

Column protectors, also known as post protectors, are protective shields that can be installed around the base of an upright to minimize damage where forklifts might hit the upright. Damage to the base of a column can weaken the entire frame and could cause it to collapse. Column protectors are made of various materials such as polyethylene, and other durable materials.

Guard rails are installed to increase protection for upright columns and for human safety when platforms or steps are attached to pallet racks.

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Other Common Types of Pallet Rack

Many types of pallet storage racks are available with different designs to fulfill specific functions or create specific advantages. When deciding on the type of pallet rack to use, several basic considerations have to be taken into account:

Desired storage density
Floor space and building height
Placement of building doors and columns
Stock accessibility
Stock rotation
Item/load size and weight
Optimal storage design
Cost of materials and installation

Some of the most common types of pallet rack systems used include:

Drive-in systems are storage rack configurations that allow the forklift to drive directly into the lane of stacked rows. Drive-in racking systems use a common entry and exit. Because a drive-in racking system has only one entrance, it uses what is called a LIFO (last in, first out) storage method. With only one entrance, the last pallet put into a row is the first one to be taken out.

Push-back systems are designed around the principle of organizing space by depth rather than width. This depth arrangement greatly reduces aisle space and increases storage density. In this configuration, each bay can be up to six pallets deep; each pallet stored on wheeled carts that fit onto rails. The rails are slightly angled toward the load/unload side of the rack in order to take advantage of gravity, saving enormous amounts of energy for moving heavy pallets. When a forklift sets the pallet onto the cart, it drives forward and causes the pallet to bump the next pallet, causing the entire row of pallets to roll backwards. When removing a pallet from the front position the remaining pallets immediately stage themselves forward so that the next available pallet can be accessed. Push back rack is a LIFO (last in, first out) storage system.

Pallet Live systems are high density pallet storage systems that utilize depth to increase capacity. This system uses a slightly inclined rail with rollers that allow pallets to move easily along the sloped plane. These systems are also called gravity flow or dynamic flow systems. The pallet flow system often has complex motion and braking systems to control the speed of the moving pallet. Pallet Flow racking systems are either a FIFO (first in, first out) or a LIFO (last in, first out) storage system. If the system is loaded from the back and unloaded from the front, it’s FIFO; if the system is loaded and unloaded from the front it’s a LIFO system.

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