Pallet Racking

Other names: Pallet Rack, Pallet Shelves, Warehouse Racks

Description

Pallet racking is a material handling storage aid system used for the storage of palletised materials in horizontal rows with multiple levels. It is a heavy-duty shelving solution for warehouse applications. 

Pallet racks are known to increase storage capacity which is why they have become common in manufacturing facilities, retail centres, warehouses, and other storage and distribution facilities. Loading materials into the racks require the use of forklift trucks. 

Manufacturers supply pallet racks in different punch-hole styles, capacities, and product quality. There are different types of pallet rack systems, the most common being: drive-in pallet racking, selective pallet racking, push-back pallet racking, pallet flow, and mobile pallet racking.

Features and Benefits of the product

• The vertical design maximizes storage efficiency and density
• Wide range of pallet racking systems to choose from depending on your storage requirements
• Increased bulk storage capacity
• Pallet flow racking systems and Carton flow racks can increase order-fulfilment efficiency
• Improves material handling and reduces damage to merchandise
• Pallet racking systems can easily be extended and adjusted as needed

Dimensions

Measuring the Pallet

Measuring your pallet racking system starts with your pallet size. You will need to take note of the weight, height, depth, and width of the pallet. A standard Australian pallet is square with a measurement of 1165mm x 1165mm. These are typically capable of holding loads up to 2,000 kg. 

Measuring Warehouse size

Having a clear picture of the overall building size can help you determine your work area and design an initial warehouse layout that you can improve as you go. Be sure to measure from the wall to wall and consider areas like offices, toilet blocks, stairs, etc. 

Other components like building columns, fire doors, electrical boxes, and the like should also be measured accurately. Measure the component’s distance from a wall to get the correct measurements, do not measure from one point to the next as it will not give you a running measurement. 

Lastly, measure the building height from the sides and middle part of the warehouse. From there, you are able to draw up a plan and find the best layout for your requirements. 

Measuring bay width and sizing

Bay width refers to the length of a beam and is measured between the insides of the frames or the structure in which beams slot into. The pallet sizes for storing will determine your bay width. Racking suppliers can provide standard beam sizes between 1200mm and 3900mm.

Moreover,  It is important that you adhere to the load limits set out in the Safe Working Load (SWL) signs. To determine the load limit of your pallet rack, measure the weight of the products to be stored on a single beam level. 

Measuring upright frame

A pallet racking frame consists of frames, uprights, and braces. Each bay in a pallet racking system has two upright frames that are connected with beams. 

To calculate your frame, you first need to measure from the base plate to the highest point of the frame. The frame depth, on the other hand, is based on the pallets you will be storing. They can range from 450 mm to 1500 mm.  

Determining bay configuration

The most important part of a pallet racking bay is the height of the first beam level to the base plate as it can affect the strength of your rack. The higher the beam level, the lower the bay capacity. Once you’ve measured that, you then need to measure the beam pitch or the distance between the top surface of a beam and the beam above it. Work out the beam pitch of each beam level by using your pallet sizes and handling equipment. 

How to measure up for the area to fit the application

When spaced too close to each other, pallet racks can damage a building component and compromise its load-carrying capacity. To avoid this, current standards require a minimum clearance from the building structure as follows:

• 1200mm clearance from the top of the top pallet to the lowest part of the building roof
• 300mm clearance from any wall or column within the building

Aside from pallet rack clearances, your pallets should also be stored within the recommended clearances to reduce damage and ensure safety. Below are the recommended clearances:

What is a pallet racking system?

Pallet racking is a material handling storage system for storing items on pallets. It is a popular shelving solution for warehouses, manufacturing, and distribution facilities as they optimize space and increase storage capacity. 

What are the different types of pallet racking configurations?

There are different types of pallet racking systems. The most common are: 

• Selective Pallet Racking - This is the most used pallet racking system as it allows users to access pallets without having to move the other. They come in two configurations, roll-formed and structural steel.  

• Drive-in and Drive-through Pallet Racking - This configuration allows forklifts to drive smoothly into a lane of bays. Drive-in systems are for aisles that use a common entry and exit point while Drive-through systems have two different entry points. 

• Mobile Pallet Racking (MOVO) - This is a dynamic racking solution where pallet racks are placed on mobile bases that run on in-ground rails. 

• Pallet flow Racking - This rack system uses a set of slightly inclined wheel tracks or pallet flow rails to move pallets from the loading end to the unloading end. It is typically used for high volume products. 

• Push-back Pallet Racking - This is a live storage system that uses push-back rollers or shuttles. Here, unit loads are stored by pushing other units towards the end of the rack. 

Does Pallet racking need to be bolted down? 

Yes, pallet racks should be securely bolted to the floor to comply with Australian standards. This is made to ensure that the pallet racking system is stable and secure. 

Anchoring pallet racks to the floor can also help protect your inventory from damage. 

How much weight can pallet racking hold?

The weight capacity of pallet racks varies across manufacturer, size, and design. Standard pallet racks can hold 1000kg pallets.

How to disassemble pallet racking?

Dismantling pallet racks depends on how they were fabricated and assembled by the manufacturer but here’s a rundown of the steps:

1. Carefully remove all the decking and accessories of your pallet racking system. This includes pieces of wire decking, shelf dividers, columns, and post protectors. 
2. Take down the beams or horizontal supports one by one according to your manufacturer’s instructions. 
3. Since pallet racks are bolted on the floor, remove the anchors by loosening the nut.. This will leave damages or holes on your concrete floor that need repairing. 
4. If you’re planning to move or transport your pallet rack, tightly bundle each component and palletisee them to avoid possible damage. 

Does pallet racking need to be certified? 

Pallet racking is regulated by Australian Standards AS4084:2012 for Steel Storage Racking. This standard entails regular inspections with a compulsory annual audit and certification to ensure workplace safety and compliance. 

However, some types of racking like Drive-in racking, Cantilever Racking, and mobile racking are excluded from these standards. 

How much does it cost to install pallet racking? 

The average cost per pallet position is around $50 to $120. However, this will vary depending on the type of pallet racking system you require.