Industrial Space Solutions Ltd.
First Floor,
Bankside House,
Hadfield Street,
Dukinfield, Cheshire
SK16 4QX
Tel : 0161 830 6890
Fax : 0161 343 5328
Industrial Space Solutions Guide To Pallet Racking
www.industrialspacesolutions.co.uk
01 Introduction
02 Pallet Racking Layout Design
03 Wide Aisle Racking
04 Narrow Aisle Racking
05 Dynamic Storage
06 Drive-in Pallet Racking
07 Overview
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Introduction
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Pallet Racking Layout Design
A properly designed rack storage system is
a key component in the effort to achieve
both customer satisfaction and continued
growth.
As more companies turn to consolidation
as a way to drive down costs, renewed
focus has fallen on the way warehouses
are racked out. Whether consolidating offsite storage or entire warehouses, uniting
stock under a single roof has put a
different slant on how racking is
configured.
Industrial Space Solutions, reckons there
are plenty of ways to eke more space out
of a typical warehouse or distribution
centre, by altering the storage and racking
design. Walk through any warehouse and
you'll notice the actual volume of stored
parts is a relatively low percentage. The
gangways, aisles, support structure for the
building and the racking all occupy a big
proportion of the total space - a proportion
that can be reduced by moving to storage
systems that offer greater density.
Versatility is a key priority. ISS believes
there is growing demand for storage
systems that meet both current and
anticipated load requirements, and for
shelving and racking systems that allow a
variety of pallet, bin and container
configurations.
Consolidating
warehouses
that
have
different activities under a single roof can
be tricky. This can lead to a bigger variety
of pallet storage with Euro pallets, Euroblack plastic pallets, slip sheets and
traditional 1,200 x 1,000 mm pallets; and
the system may need to cater for all of
these.
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Looking at the racking itself, customers are asking if this can be easily
reconfigured, for example can the racking systems offer a variety of different
upright heights to accommodate a range of pallet loads, as well as beams
constructed for a range of bay widths that will facilitate a wide range of
location configurations for an order picking operation.
Need more warehousing pallet racking storage space?
Don't want to (or cannot) move, then you need to maximise every ounce of
space out of your present building layout design.
To help determine the right pallet racking for
your needs, you need to answer a few simple
questions.
1) What size pallets will you be using?
2) What height do you need?
3) What beam size and load capacity do you
need?
4) Do you need wire decking or pallet supports?
The answer to these questions will help
in the layout of your pallet racking
system, using the warehouse space you
have to the fullest. Another item of
importance is what type of forklift are
you using? The forklift mast height will
have a bearing on the height of the
uprights for your pallet racking. Aisle
width will also be determined by the
forklift style, as some forklifts require
more aisle spacing than others.
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Pallet racking is essential to modern
warehouses, retail centres and other
facilities. It enables the efficient
storing and moving of goods. Pallet
racks link together to form pallet
racking systems. These can be vast,
depending on the space available and
the nature of the application. In all
pallet
racking
systems,
space
utilisation is vital to achieve the best
results. This is known as maximum
storage density.
A pallet rack has numerous structural
components. Pallets rest on horizontal
struts called beams. Beams mount onto
upright frame columns (also called
columns or uprights) using clips or
bolts known as pallet supports.
Diagonal and horizontal braces welded
into the frame provide extra strength,
stability and rigidity. This structure is
the basis of pallet racking.
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Wide Aisle Racking
What is it?
Wide aisle pallet racking is the most popular system for
storing palletised loads. The technology consists of
upright frames and horizontal beams that interlock to
form the racks construction.
Each pallet is supported individually within the rack and
is independently accessible. The racking requires no
specialised handling equipment and can be easily
utilised for any type of warehouse environment. This
makes wide aisle racking a versatile choice and its
broad flexibility is one of the many benefits that derive
from this system.
Racking can be configured to a minimum aisle width of
2.5 metres when a reach truck is used. A standard
counter balance truck can operate in a minimum aisle of
3.5 to 4 metres. The only restriction with using these
types of trucks is that the maximum height of the
racking is determined by the lift height of the vehicle.
What are the benefits of this system?
Wide aisle racking provides high quality, easily
accessible storage. It utilizes 40% of floor space and
allows fast throughput. It also means that loading and
unloading is straightforward and trouble-free.
Where would it be best suited?
Any situation where space is not a constriction. Most
large grocery warehouses use this type of racking
technology because it can be easily adapted for peaks
and troughs in demand.
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Narrow Aisle Racking
What is it?
Narrow aisle pallet racking is used in
places which are a little tighter on
space. A reduced aisle width of around
1.8 metres means floor space is much
better utilised, increasing it to 45%.
Narrow aisle forklift trucks must be
used, but it means that the space you
have within your warehouse can be
managed a lot more efficiently.
Narrow aisle trucks are classed as
specialist machinery and can lift higher
and work faster than standard counter
balance trucks. This has a beneficial
effect on your business.
As trucks such as these do not turn in
the aisles, they need a guide rail or wire
guidance system. This allows them to
manoeuvre round the racking with a
high degree of precision. The advantage
of using wire guidance is that is it
embedded in the floor. This keeps the
floor clear of obstructions and is easier
to clean.
Each pallet is supported in a narrow
aisle configuration, which means that
accessibility and stock rotation are as
good as a wide aisle system.
What are the benefits of this system?
Narrow aisle racking provides a better floor
utilisation of 45%, making it ideal if you are short
on space. The pallets are easily accessible and the
type of forklift trucks used means optimum
efficiency can be achieved. The way the racks
have been designed means stock rotation is easy.
Where would it be best suited?
If space is proving to be something that must be
managed carefully, then narrow aisle racking is
the perfect choice. It is also ideal for storing
items such as electrical goods, hardware, textiles
and paper.
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Dynamic Storage
What is it?
Dynamic storage is also known as live storage. It consists
of any of a number of systems that can be added to pallet
racking to work with pallets, tote boxes and cartons.
Dynamic storage racking comes in three different forms.
Each of these is detailed below.
Pushback
This method uses special beams and pushback assembly
subframes running front to back in each bay. The tracks
are mounted at an angle so when a forklift truck pushes a
pallet into a bay, the one that is already there is pushed
backwards. When the pallet at the front is removed, the
one behind it will roll to the front.
One of the features of this system is that the pallets can be
stocked four deep, conserving space and allowing easy
organisation of your stock.
Carton Live Storage
This is a design which works by inserting goods into the back of the structure and
removing them from the front.
This is an excellent method of storage because it means perfect stock rotation will be
achieved. It also offers a good storage density and each carton is supported providing a
high level of quality storage. Picking errors can be minimised by giving each product a
dedicated lane.
Pallet Live Storage
This works in exactly the same way as carton live storage
except on a much bigger scale. Whole pallets can be stored
in this way making it ideal for fast moving, perishable
goods that are received and despatched in large quantities.
One of the main features of using this system is that any
size and shape of pallet can be handled.
Where would it be best suited?
Dynamic storage is suitable for goods that perish quickly
(e.g. foodstuffs). Products such as this must be received
and delivered rapidly and this method ensures that stock
rotation can be matched perfectly with expiry dates.
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Drive-in Pallet Racking
What is it?
Drive-in pallet racking assembles the pallets in a
solid unit, as you can see from the diagram. This
means that space utilisation is increased to 85%,
one of the main benefits of using this system.
This high storage density is produced by
removing lanes and aisles from the rack
structure. The cost of this is selectivity; the first
pallet into a lane will be the last out. However
many products are received and shipped in
batches, so this is not a disadvantage.
Standard forklift trucks can be used with
great speed
in a system such as this, driving
in and out of the lanes to pick and
place pallets. This operation
can be refined even more by
using lead-in rails
and guidance rails within
the lanes.
What are the benefits of this system?
If storage capacity is one of your main priorities
within your warehouse, then drive-in racking is a
good solution. It provides a very high storage density
and optimises space to the maximum level. It also
has the added advantage that each pallet is
supported individually, so damage from crushing is
eliminated.
Where would it be best suited?
This racking system is the right choice for seasonal
goods where input and output are at different times.
Also when pallets are despatched in batches (e.g.
soft drinks, paints and chemicals).
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Overview
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 (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 railguided 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.
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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.
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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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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.
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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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Industrial Space Solutions Ltd.
Bankside House, Hadfield Street,
Dukinfield, Cheshire, SK16 4QX
Tel : 0161 830 6890
Fax : 0161 343 5328
maximising the
investment potential
for your industrial &
commercial property
Services :
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Contacts :
David Burke
Mob : 07825 368086
david@industrialspacesolutions.co.uk
Andrew Littler
Mob : 07900 270023
andrew@industrialspacesolutions.co.uk
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