Pallet Rack Design

Pallet rack design can be a complicated process. It’s important to figure out the needs and physical limitations of your business before investing in a pallet rack system. The following information outlines the information needed for purchasing the proper racking. By printing this article and filling in the blanks, you will be prepared to answer the questions you will be asked when ordering your custom pallet rack system. To purchase a pallet rack system visit www.pallet-rack.net or call 1-800-338-1382.

Step 1. Length of Beam
Select which type of lift truck you will be using.
Counter Balanced Truck	Straddle or Outrigger
For Counter Balanced Maximum width of pallet or load (whichever is larger) __________ Number of loads across (between upright frames)_______________ Allow 3″ between upright frame and loads. Allow 4″ between loads Example: Allow 10″ for two across storage. Total length of beams (Max load width plus allowance) The clear distance between posts will be beam lengths plus space between plate and columns.	For Outrigger or Straddle Inside Clearance between outriggers ____________X 2=_____________ Width of outriggers plus 3″__________ x 3=__________________ *Total Beam length ___________ *If load overhangs outriggers, add amount of overhang for each load.

Load Types This diagram shows the difference between wing and flush pallets.

A) Depth of pallet or load B)Width C) Height D) Total Height (load and pallet) E) String Dimension F) Total Weight (load plus pallet)

Step 2. Beam Capacity
Number of pallets____ X load weight = required capacity per pair____Beam capacity ___ lbs. for ___length = type____________
The beam capacity chart represents the uniform distributed load to be carried by a pair of beams. For single level racks, decrease beam capacity by 15% to account for the reduced end fixity, and use only heavier beams, which have four hook end connectors.

Step 3. Frame Depth and Spacers
Frame depth A). should be 6″ less than pallet stringer dimension________________ (must be in 3″ increments) Row Spacers and Wall Fixes Suggested row spacer length: Amount of pallet or load overhang___________ x 2 ___________ Add 6″ (suggested clearance)=_____row spacer length Wall fix: pallet or load overhang:___________ + 6″__________ wall fix length__________
Pallet Guide A: Depth (Stringer Length) B: Width (Board Length) C: Height

For more information on Pallet Rack systems visit www.pallet-rack.net or call 1-800-338-1382

Step 4. Frame Upright Height
Starting at floor level: Add height of pallet and load (A)_________ (B) and (C) or use 9″ Add clearance between top of load and bottom of beam (B)____________ Add thickness of support beam Total_______________________ Multiply total times the number of shelf levels _________ to equal frame height
Rack is required to go only as high as is necessary to support top pallets. Height may also be limited by the extent of fork elevation of lift truck. Provide a minimum of 6″between top load and ceiling obstructions. (Check local fire codes)

Step 5. Frame Capacity
Add total of loads supported by shelf beams___________ Determine maximum vertical shelf spacing (x)__________________ Determine number of levels per bay___ and bays per row___________

For great deals on pallet rack systems visit www.materialflow.com or call 1-800-338-1382

Pallet Racks: Specialized Storage

In addition to standard pallet rack systems there are many specialty racking systems available. These racks are great for specific products and high flow situations. Read the guide below for more information on these specialty racks.

Flow Racks Flow racks allow products to flow from back to front. When loaded properly the oldest inventory is removed first. Thanks to their clever design they can increase productivity and reduce worker fatigue. These racks are available in several specialized configurations including: pallet gravity flow, greenhouse gravity flow, hospital gravity flow, and mobile flow. These racks are great for high flow applications where inventory is quickly coming in and going out. For more information on flow racks go here…

	Drum Pallet Racks
	Drum Pallet Racks are designed to store high capacity 30 and 55 gallon drums. The great thing about these racks is that the drum cradles are removable, allowing standard pallets to be used if desired. To purchase this rack go here…

Backstock Racks Backstock Rack is one of the most economical storage solutions. It’s great for storing bulky products and the high strength steel beams with wood decking ensure durability. To purchase this rack go here…

Tire Racks This tire rack is designed to keep tires organized and out of the way. Perfect for service shops, car dealerships or even an auto enthusiast’s garage. To purchase this rack go here…

Cylinder Pallet Racks These pallet racks safely secure and store cylinders. This unit features fork pockets and access to individual cylinders. Casters are also available. Perfect for storing those loose helium containers. To purchase this rack go here…

Cascade Storage Rack User Manual

In order to get the most from you storage rack system it is imperative that the rack is properly assembled and maintained. The information below will assist you with your responsibility of providing a safe storage rack system. Contact Material Flow at 1-800-338-1382 for more information.

Storage racks should only be assembled by trained personnel who have experience with rack assembly.

Improper rack assembly can reduce efficiency and pose safety risks. If you are not familiar with rack assembly you should contact Material Flow for professional assembly. Material Flow cannot provide or guarantee warranty services if your rack is assembled improperly. Call us at 1-800-338-1382.

It is imperative that rack structures are installed on a plumb, level, and square fashion. Since most floors aren’t perfectly flat shims are often required. A four foot long carpenter’s level is great for checking level and plumb specs on a storage rack of reasonable size. A vertical tolerance of 1/8” in 4 feet is generally acceptable. (Building code for floors is + or – 1/8” in 10 feet.) Changing configurations (such as adjusting storage levels) can adversely affect load carrying capacity and structural integrity of the rack system. Before adjusting rack configuration contact Material Flow to double check the safety and structural soundness of the new configuration.

“Nut and Bolt” connections are to be tightened to a snug and secure condition. 60 foot pounds is recommended for ½” diameter hardware. Avoid tightening components to the point of crushing.

Safety locks on bolt-less connections must be fully engaged through the beam connector and upright column connector holes. Safety locks help prevent accidental dislodgement of the load beams. Locks should engage automatically; however, the beam needs to be fully seated in the bottom of the teardrop shaped connector hole.

Do not use beams with damaged or missing safety locks. Contact Material Flow for extra safety locks.

Every Column of each rack frame must be anchored to a sufficient concrete floor. A normal anchor connection is on ½” diameter X 5 ½” or as indicated on the Material Flow installation drawings. (3 ½” embedment is code.) Anchor bolts are not included with our rack systems unless detailed on the invoice. Because concrete floors can vary greatly in design and load capacity Material Flow cannot guarantee that a specific concrete slab is suitable to support a particular rack installation. The characteristics of the slab should be obtained from the building’s architect before the racks are ordered to ensure the proper rack for the specific slab.

Racks are not to be installed outdoors unless specifically designed by Material Flow for this purpose. Outdoor usage requires consideration of winds, snow, and other variables not normally considered in rack design.

Be cautious when mixing new and existing parts. Components from the same company can vary in design. Manufacturers often modify basic designs over the years to improve performance. These differences can affect safety and lead to dangerous situations. While it may be possible to assemble a rack system with parts from different manufacturers Material Flow can only warranty and guarantee systems built with genuine Cascade parts.

Installation of capacity plates is highly recommended. These plates specify load size, load weight, and rack configuration. These plates communicate important safety information for both present and future users. Several signs should be posted to maximize visibility. Signs can be procured through Material Flow.

Never climb on racks during or after assembly. Storage racks are not designed to be stepped or climbed on. Serious injury may result from doing this. It is your responsibility to communicate this warning to those who use and come into the area of your storage system. Prominently placed signs are very helpful, especially if your rack is in a retail environment.

Allow adequate aisle spacing. Aisles that are too narrow for handling equipment increase the danger of collisions between lifting equipment and rack structure. Collisions can result in items falling or broken products.

Maintain sufficient clearances around loads. These include clearances dictated by fire codes (between loads in back to back rows and overhead between top load and ceiling structure). Also between adjacent loads horizontally and between loads and rack horizontal and vertical members. Tight clearances decrease handling speed, increase fire risk and the likelihood of damage to rack systems.

Install good lighting in every rack aisle. Good lighting improves handling efficiency, prevents accidents and reduces damage to rack systems.

Install optional column protectors at aisle facing columns, and guard rails at ends of rack rows. These devices provide a physical and visual barrier against handling equipment impacts. Material Flow has a large selection of these devices.

Do not cut, weld or in any other way modify any component of your Cascade storage rack. These modifications can jeopardize the structural integrity of your rack structure. Any modification except performed or authorized in writing by Material Flow personnel will make null and void any warranties and guarantees.

Use only high quality pallets. Broken, cracked, or poor quality pallets can cause falls from racks, or cause dynamic racks to become jammed or inoperable.

Perform regularly scheduled inspections and maintenance at least once a year.
Inspect:
All hardware for tightness (including anchors)
All beam safety locks for operation and engagement
All racks plumb, square, level
No dents, knicks, or damaged components
Load sizes and weights match original specs.
Check finish, touch up chips or scratches to prevent corrosion

Replace damaged or missing beam safety locks immediately! Do not use beams without safety locks. Unload damaged racks immediately and contact Material Flow for replacement parts.

Minimize contact between storage racks and handling equipment. This is the key to improving rack longevity. Educate rack users to avoid dropping loads onto rack, how to position material correctly and how to report rack damage.

Do not overload any rack system or component. Storage racks are designed for specific weights. Should your load weight requirements change contact Material Flow before using the rack for new loads. Overloading racks can result in damaged material and severe injury.

Other Precautions: When using a fork truck be sure that the truck is equipped to protect the operator from accidental crushing against storage, rack loads, or other objects. If your fork truck lacks these features contact the manufacturer/reseller of the fork lift equipment and get the proper safety equipment installed.

Make sure that your fork truck is equipped to protect against accidental falls. Platforms where operators stand must be approved by the manufacturer and OSHA. Operators should always be restrained and protected from falling off equipment.

Keep work area clean. Keep aisles clear of trash or obstruction. Do not stack pallets on floor, keep floor surfaces clean and free of moisture.

Questions about Cascade Rack?
Material Flow & Conveyor Systems
800-338-1382 or 503-684-5133
11117 SW Greenburg Road
Tigard, OR 97223

Pallet Rack: Things to consider before buying

Purchasing a pallet rack system is a big investment. The guide below outlines several considerations to make before purchasing a rack system. For more information visit Materialflow.com or call 1-800-338-1382

1. Responsibility between lift truck and rack system. Who will take it?
2. Is there enough aisle spacing to operate the truck? Pallet rack is one thing; drive-in rack requires another aisle spacing. Pushback and pallet flow rack take up to 1′ 6″ more aisle space than pallet rack. Because the truck must go straight in and out of the system, the operator can’t begin to turn into the load before being straight in front of it.
3. 95% of all rack collapses are due to operator error. Abuse is just like a car. Sometimes it is driven off the lot and totaled within one day, sometimes the car never gets into a wreck.
4. Know your loads by weight. Don’t guess. Overloading can be a real problem.
5. Be honest about your operators. If you already have rack abuse you will continue to have it. Ways to change this pattern: A) additional training, B) wider aisles, C) cutting cross aisle traffic down.
6. Design from the inside out, not the other way around.
7. Look at your competitors’ facilities. Not all companies are the same.
8. Anybody can sell rack. New or used. But what do you get? Is it the right height, depth or type?
9. Don’t buy a piece of lift equipment before you buy your rack system. Remember lift truck houses sell lift trucks because that is what they are supposed to do, just like a car dealer.
10. Everybody wants their product like Burger King. They are in such a rush to get it off their desk that they many times make a mistake. For some reason there always seems to be enough time to get it corrected but not enough time to do it right in the first place. Remember to allow enough time to plan, don’t rush.
11. When should you replace a rack? A) Broken welds on upright, B) Beams creased or bowed in, C) Column off of footplate.
12. A pallet should overhang a beam by 3″ front and back in order for the stated capacity to be valid, otherwise the capacity has to be down-rated.

    For more information visit Materialflow.com or call 1-800-338-1382