Proper Sizing & Selection of Frames & Beams

Determining Frame Depth
The depth of the frame is determined by the size of the pallet. The most common pallet used is a 40″ wide x 48″ deep GMA wooden pallet. Using that as a guideline, the pallet should overhang the beams 3″ in the front and 3″ in the back thus making the frame depth 42″. The reason for this RMI rates beam capacities with 3″ front and back. When the operator is putting pallets away in the upper levels, it is wise to allow overhang so that the driver doesn’t inadvertently miss the beam when setting the pallet down.

Stromberg Rack 101

Stromberg Rack products a variety of racking products:

The first is our I-Series or Teardrop roll formed pallet racking with an adjustability of 2″ centers. This is the most common of rack patterns throughout the United States.

The second is hot rolled structural rack which is bolted together.

Pallet Rack Common Terms

Upright Frame – also known as an upright or a frame. The vertical members are made up of two columns with diagonal and horizontal bracing welded between them.

Beam – the horizontal member which attaches to the upright frame columns. Adjustment is on a 2″ centers.

Footplates – steel plates welded to the bottom of the columns. Our roll formed rack generally has 5″ x 7″ x 3/8″ footplates with two 9/16 holes for use with 1/2″ lag bolts. Many times footplates are larger depending load conditions and the seismic zone.

Bracing Panels – this term is used to describe two horizontal braces and the diagonal between them within a frame. They are welded to the inside of the two frame columns.

Bay – this term is used to refer to 2 uprights with beams between them. A starter bay consists of 2 uprights and beams and an add-on bay in the same row consists of one upright plus beams.

Row – consists of a series of interconnected frames and beams.

Row Spacer – the steel member used to tie uprights together back to back. This forms a double row. There can be triple and quadruple rows when using double reach tracks. Common row spacer lengths are 6″, 8″, 10″ and 12″.

Step – the ledge created in our beams when they are formed. The step is commonly used to hold front to back member such as flanged steel cross bars, 2″ x 6″ lumber or wire deck panels. The step helps strengthen the beam section.

Selective Pallet Racks

There are three basic components of a selective pallet rack.

A) Upright frame: This consists of vertical columns, footplates and horizontal, diagonal and or cross braces. Horizontal shelf beams connect to the upright frames which forms a storage level onto which a palletized load is placed. Generally, two pallets wide is the most common configuration. Three pallets wide is sometimes used for lighter loads. Racking is often arranged in rows of two or more bays, extending in a down aisle direction.

There are many accessories to selective rack examples are listed below:

Decking: Plywood, particle and the most common decking wire mesh panels with channels.

Cross Barmembers or Front to Back Supports: Steel drop in cross bars, double flanged cross bars, 2″ x 4″ wood stringers, 2″ x 6″ wood stringers, the 2″ x 6″ members are the most common.

Other Accessories: Drop on drum supports, drop on skid supports, row spacers, wall ties, overhead top ties, just to mention a few.

Mobile Aisle Storage Systems

Mobile shelving or storage systems can seem complex at first glance but in reality they are very simple. Shelves and racks are installed on wheel carriages that are mounted to rails or tracks. The shelves then move on the rails to create an aisle. A mobile storage system can increase storage capacity by 100% as compared to a fixed system taking up the same amount of space. Mobile shelving takes up so much less space because instead of having an aisle for each shelving unit, it only needs one aisle for the entire system.

Other Benefits of Mobile Storage/Shelving System:
•Maximum density with 100% selectivity in most cases.
•Works with most order picking methods and equipment.
•Money is spent on storage, not aisles. Standard storage systems are typically only 40% storage and 60% aisle.
•Units provide extra safety and security when in the closed position.

A mobile storage system does cost more than standard storage rack. Here are a few examples of when a mobile storage system may be justified.

•If cost and availability of land or floor space is at a premium.
•If security is a problem.
•If energy prices are too high. (A smaller footprint takes less energy to heat or cool)
•If reduced stocking and picking time are desired.
•If reduced labor costs are desired.

Storage Rack Overview

Industrial steel storage racks are designed to store palletized, containerized or large unit loads placed in the rack by material handling equipment. Think of steel storage racks as a super heavy duty shelving system. Here are the most popular types of steel storage rack systems.

Selective Pallet Racks: Made up of upright columns, cross braces and shelf beams, this simple system forms a storage level which allows loads to be placed. A single row of selective pallet rack can be accessible from both sides.

Moveable Shelf Racks: Movable shelf racks have the same basic features as selective pallet rack, the only difference being that the shelves are adjustable allowing shelving to be changed to match the loads being placed on it. The shelves can also be used as pallets when not in use.

Drive-In and Drive-Through Racks: This style rack allows fork lift truck operators to drive through or into the rack unit. This reduces the amount of aisle space taken up by the rack unit. Drive-In and Drive-Through racks are made up of anchored and braced upright columns attached at the top with load rails attached to the upright columns. Drive-In rack only allows one entry point while Drive-Through rack is accessible from both sides.

Stacker Racks: Also known as AS/RS and high rise racks, these racks have a much taller footprint than their standard rack counterparts. Some systems are built up to 100′. Stacker racks incorporate a fixed track design that that can service systems much higher than standard lift equipment. Many times these systems are constructed with the building to from r rack supported building.

Cantilever Rack: Cantilever rack is a basic rack system that is made up of two vertical columns attached to two load bearing arms. This type of rack works well with long items including, sheets of wood, pipe, and carpet rolls.

Pallet Flow Racks: Pallet flow racks use the same basic framework as selective rack but have inclined conveyor wheel sections running from front to back. The pallets are loaded at one side of the rack and selected from the other. This is an excellent system for fast moving products and allows the first loaded pallet to be the first taken pallet, great for products with an expiration date.

Stacking Racks: Stacking Racks allow pallets to be stacked on top of each other. Quickly disassembles when not in use.

Structural Cantilever Rack

Structural Cantilever Rack

Structural Cantilever Storage Rack is perfect for retail or warehouse environments and works well with lift trucks. Many systems are available for use and outdoor and come in corrosion resistant finishes. Light and heavy duty models are available and in a variety of styles. Some common uses of structural cantilever rack include:

• Plywood
• Lumber
• Furniture
• Appliances
• Pipe
• Sheet Steel
• Tubing
• Doors
• Boxes
• Pallets
• Conduit
• Building Materials

To purchase cantilever rack visit materialflow.com. They have cantilever racks for all applications. F.O.B. points all across the U.S. ensure the lowest shipping costs. Call them at 1-800-338-1382.

Over-Dock Pallet Storage Systems

Dock areas are one of the busiest areas of any warehouse, or production plant, they can also be one of the most dangerous. Loose pallets can trip workers, and are known to be a fire hazard. One solution to this problem is the use of an over-dock pallet storage rack. This racking system allows pallets to be stored over docking areas and keeps pallets off the ground. Contact Material Flow at 1-800-338-1382 for more information on this great system. To reduce the risk of pallet fires consider using plastic pallets.

Pallet Flow Rack: Enhancing Order Picking

Pallet flow rack saves time and money by dramatically reducing the time required for order picking. A well designed carton flow rack system keeps the most popular products at the ideal level for workers and allows the oldest products to be taken first. Pallet flow rack are equipped with either skate-wheel or ball bearings depending on the application. Many systems are designed to work with existing pallet rack, this allows for a combination of pallet rack and flow rack; the best of both worlds. Another benefit of flow rack is that tilted shelves reduce worker fatigue and injuries by keeping product at the front of the shelf, no more bending and stretching. Pallet Flow Rack will also increase space utilization in your existing structure, helping defer or avoid the costs of building and maintaining new structures.

Successful Pallet Flow system designs require the following:

• An experienced vendor, to ensure the initial system design is appropriate for your application.
• Installation by experienced personnel who understand the ins-and-outs of making these systems function properly.
• A durable structure to support the flow lanes. Use high quality pallet rack that is built to last.
• A knowledgeable system integrator, with a working knowledge of how to combine your flow rack system with other elements of your storage facility, such as Pick Modules, Push-Back Racks and more.

Material Flow and Conveyor Systems is one of the largest pallet rack dealers on the west coast, give them a call at 1-800-338-1382

Mezzanines: The Perfect Addition to Pallet Rack

Mezzanines are one of the most cost effective investments a company can make. A mezzanine can double floor area, provide twice the number of “picking fronts” and offer twice the cube utilization. Another benefit of mezzanines is the cost. A typical mezzanine offers three times the space of a new building for the same amount of money. Because mezzanines aren’t stand alone structures they offer several tax benefits as well as increased depreciation. Mezzanines are great for using space that would otherwise go wasted. They can be placed above existing shelving or racking and add even more storage through the use of drawers, shelving, or cabinets.

Building Requirements
Mezzanines require a ceiling height of at least 14″ floor loads in excess of 150 lb. per square foot, a minimum of obstructions in all three dimensions and a building lease that allows modifications and customization. Dual level sprinklers are usually required and changes to lighting, HVAC, and other systems are typically needed. Attaching a mezzanine to a building makes it under the jurisdiction of local building codes.

Use
Adding a mezzanine will change the handling methods used by operators and should be considered when planning and designing a mezzanine. The best way to setup materials with a two level setup is to keep fast moving product families on the lower level and slow moving product families on the top. The biggest mistake made with two level storage is to only split up slow and fast moving products without thinking about keeping similar product families together. Access to mezzanines can be accomplished using ladders and stairways. Materialflow.com has a huge selection of OSHA approved ladders.

If your warehouse or plant is in need of more space consider a mezzanine. It’s much cheaper than buying new land and you can take it with you if your business ever moves. A great place to purchase mezzanines is Materialflow.com. They have a large selection and a great staff that knows the ins and outs of material handling. Give them a call at 1-800-338-1382.

Selecting the Right Pallet Jack.

If your warehouse has a pallet rack, chances are your company has a fleet of pallet jacks. With so many to choose from it can be hard to decide which one matches your needs. This quick list gives a rundown on some different types of pallet jacks and their uses.

• Non-Corrosive: Great for wet or corrosive environments, these stainless steel pallet jacks can be washed down and are great for pharmaceutical, food and wet environments.
• All Terrain: Sometimes materials need to be moved over rough surfaces. These pallet jacks can plow through the toughest terrain. Great for construction sites!
• Scale Equipped/Freight Saver: These pallet jacks can reduce wasted time in shipping departments thanks to their built in scale. Instead of having to weigh items before they go on the pallet jack, they can be weighed while on the pallet jack.
• Wheel-Nose: Wheel-nose pallet jacks are perfect for tight spaces. Their extra maneuverability allows them to position goods closer together than that of a standard pallet jack.

Choosing the correct pallet jack for the job will save you money and time. For a large selection of pallet jacks visit Pallet-Jack.org or call Material Flow at 1-800-338-1382.