Pallet Racking

Pallet racking is a perfect way to optimize space in your warehouse. Pallet racks are versatile structures designed to store products in a systematic and accessible manner. Pallet racking systems enhance operational efficiency by allowing quick access to goods, improving inventory management, and optimizing floor space.

Types of Pallet Racking

The most basic form and most popular form of pallet racking is Selective Pallet Racking. You can design this style of rack to accommodate various material sizes. These racking systems are called “Selective” because they allow users to select any pallet in a first in, first out process from the racking system without having to relocate other pallets first.

If you are needing a different style other than Selective, the options are endless. Here are a few other styles of pallet racking that might be the perfect fit for your warehouse.

Drive-In Rack

A drive-in pallet racking system is a highly efficient “last in, first out” storage solution widely used for handling high-volumes in warehouses. It maximizes storage density by stacking pallets on static rails, minimizing the need for aisles and optimizing warehouse space. This system allows for easy scalability without requiring additional warehouse space leases or purchases. Its simple design and low retrofitting requirements make it cost-effective and straightforward to maintain, offering versatility for storing large quantities of homogeneous materials with minimal assembly and maintenance costs.

Carton Flow Rack

This style of pallet racking is an easy and fast picking system. This is great for hand picking small items for orders. Cartons or boxes are loaded on one side of the rack system then will slide down a wheel bed on the other side to be picked.

Gravity Flow Rack

Gravity flow racking utilizes gravity to load, organize, and retrieve cartons or pallets in warehouses, promoting space maximization, productivity improvement, and enhanced employee safety. These systems operate on a first in, first out (FIFO) basis, where items automatically move forward as space becomes available, facilitated by wheels or rollers on sloped shelves. Gravity flow racks offer high-density storage and customizable configurations for pallets and cartons, making them ideal for pick modules, where quick access and efficient turnover are crucial.

Pallet Flow Rack

This style of racking is good for “First In, First Out” storage. You load material from one side and pull material from the other. Pallet Flow racking maximizes storage by minimizing the aisles. This style of storage can hold up to 20 pallets deep.

Pushback Rack

A “Last In, First Out” storage option. This style of rack uses carts that sit on rails in the racking. You can store anywhere from 2-6 pallets deep. Once a pallet is removed gravity will move the next pallet into place.

Cantilever Rack

Cantilever racking is designed for storage of longer, thinner items like steel racks, beams, and lumber, as well as bulky items that are challenging to store on traditional shelving systems. Its open design and long beams facilitate easy access to items, particularly those stored at higher levels reachable by forklifts, minimizing the risk of items being obscured by others. This racking provides flexibility for vertical storage. Implementing cantilever racking can save both time and money by streamlining storage and retrieval processes and optimizing overall warehouse space utilization.

As you can see there are many options of racking for your warehouse. If you are thinking about upgrading, adding on or starting from scratch please contact American Material Handling to help you get your warehouse functioning with the correct style of pallet racking.

Interior of a large warehouse featuring tall, empty metal pallet rack shelving units in green and yellow. The pallet rack shelves are arranged in rows, creating a spacious storage area. There are two green scissor lifts parked in front of the pallet rack shelves, indicating ongoing or recent installation work. The high ceiling with industrial lighting provides bright illumination throughout the space. The concrete floor is clean and the overall environment appears organized and well-maintained.

Interior of a large warehouse with long rows of tall, blue and red metal pallet rack shelving units. The pallet rack shelves are empty, with wire decking in place to hold items. The pallet rack shelves extend far into the distance, creating a sense of depth and vast storage capacity. The high ceiling with bright industrial lighting provides ample illumination throughout the space. The clean concrete floor adds to the orderly and spacious environment.

Interior of a large warehouse with stacks of green metal pallet rack shelving frames arranged in tall, neat piles. The pallet rack frames are organized along a spacious aisle, creating an orderly storage area. The high ceiling with industrial lighting illuminates the space, highlighting the extensive inventory. The concrete floor is clean, and the environment appears well-maintained and efficiently managed.

A warehouse interior features a tall, multi-tiered drive-in rack shelving system with blue metal frames and orange horizontal supports. The shelving units are extensive, forming a grid of tall, narrow aisles that reach up to the high ceiling. The floor is made of polished concrete, and the entire setup appears robust and designed for heavy-duty storage. Safety signs and a fire extinguisher are visible on one of the columns, indicating attention to safety regulations. The overall scene suggests a well-organized and spacious storage area, ready to hold a large volume of inventory.

A spacious warehouse containing large stacks of metal pallet rack shelving frames in various colors, including yellow, blue, and gray. The pallet rack frames are neatly arranged and piled high, showcasing an organized inventory. The warehouse features a high ceiling with industrial lighting, highlighting the structural details of the shelving units

Interior of a large warehouse featuring tall rows of blue and orange metal pallet rack shelving units. The pallet rack shelves are labeled with large letters, such as "E," "F," "G," and "H," for easy identification and organization. The aisle is wide and clean, with bright industrial lighting illuminating the entire space. The high ceiling and extensive shelving create a sense of vastness and efficient storage capacity in the warehouse.

A cantilever pallet storage rack with blue vertical supports and orange horizontal arms holding various metal beams and profiles, located outdoors under a clear blue sky. Some materials are stacked neatly on the racks, while others are wrapped in protective covers. The scene is set in an industrial area with a white building in the background and trees visible in the distance.

Close-up view of a warehouse storage rack holding long pipes. The pipes are stored vertically and supported by green metal frames with orange brackets. The pipes are neatly organized in rows, creating an orderly and efficient storage system. The environment appears clean and well-maintained, indicating an organized facility.

Benefits of Pallet Racking

Pallet racking systems offer numerous benefits to warehouses and industrial facilities:

Maximized Space Utilization: Efficiently utilizes vertical space, maximizing storage capacity without expanding the warehouse square footage.

Improved Inventory Management: Facilitates systematic organization and clear visibility of inventory, enhancing inventory control.

Enhanced Workplace Safety: Ensures stable storage of heavy pallets and provides clear aisles for safe movement of personnel and equipment.

Increased Productivity: Streamlines picking and replenishment processes, leading to faster order fulfillment and reduced turnaround times.

Cost Efficiency: Reduces operational costs associated with storage by optimizing space and improving inventory management practices.

Flexibility and Scalability: Offers flexibility to adjust configurations as per changing storage needs and scale operations seamlessly.

Pallet Racking Accessories

There are several key components and accessories which are central to pallet rack functionality that work to optimize space utilization and enhance operational efficiency. Beams, uprights, wire decking, pallet supports, column and aisle supports form the foundational elements of pallet racking systems, each playing a distinct role in ensuring stability, safety, and accessibility of stored items. Understanding the functionality of these components is essential for designing a racking system that meets your specific storage needs while adhering to safety standards and maximizing warehouse space.

Uprights

Uprights are the vertical frames in pallet racking systems that are designed to support the structure of the entire pallet rack. Uprights are anchored to the floor and multiple slots that allow adjustable positioning for pallet racking beams.

Beams

Beams in a pallet racking system, are the horizontal bars that are crucial for structure and storage efficiency. Beams are designed to withstand considerable weight loads ensuring the safety and storage of heavy objects.

Wire Decking

Wire decking, used in pallet racking to increase product storage flexibility and safety, features a durable metal open-weave design that fits between or over pallet rack support beams. This design enhances storage safety by distributing weight across the beams and prevents product loss and spills by catching items that may fall from pallets, thereby safeguarding stored goods and maintaining warehouse cleanliness.

Pallet Supports

Pallet Supports are a less versatile but less expensive option to wire decking. Pallet supports are designed to prevent pallets from falling between the beams and provide “insurance” from damaged or irregular pallets and forklift driver error. These supports also provide the forklift operator with the ability to reposition a misaligned pallet, promote longer pallet life by more evenly distributing weight, prevent large items from falling through the rack, protect inventory from damage, and are preferred in double-deep racks to prevent potential hang-ups on wire decks. Additionally, they prevent beam twisting in structural rack systems, thereby increasing beam load rating and capacity.

Column and Aisle Supports

To protect your pallet racks, invest in column and aisle pallet rack protectors designed to prevent accidental damage to pallet rack columns and posts. Loading and unloading operations, particularly with forklifts or similar equipment, often lead to pallet rack damage, underscoring the importance of installing protectors whenever feasible.

A green pallet rack upright frame with diagonal and horizontal braces for added stability. The upright is perforated with evenly spaced holes to allow for adjustable shelving heights. The frame is part of a larger racking system, with the rest of the structure shown in a faint outline, highlighting the upright as the main focus.

A bright orange pallet rack beam installed on a white racking system. The beam is secured between two upright frames with perforated holes for adjustable shelving heights. The orange beam stands out prominently against the faint outline of the rest of the rack, highlighting its placement and function within the larger structure.

A wire deck made of sturdy metal grid, featuring three reinforced support channels running horizontally. The deck has a flat, rectangular shape, designed to provide a strong and stable surface for storing items on warehouse racking systems. The metal wires are closely spaced to ensure safety and durability.

A reinforced metal rack post with a perforated design stands upright, supported by a base plate bolted to the floor. The post features an additional reinforced sleeve that wraps around the bottom portion, providing extra strength and protection against impact. Diagonal support braces are attached to the post, connecting it to another base plate, enhancing stability and rigidity. This setup indicates a repaired or reinforced shelving unit intended to bear significant loads and resist damage in a warehouse or industrial setting.

Close-up view of two blue metal pallet rack shelving upright frames. Each upright frame consists of a vertical post with perforated holes for adjustable height settings and a larger, hollow rectangular piece that fits over the post for added support. Both frames have base plates for secure anchoring to the floor. The design is robust, suitable for industrial use in a warehouse or storage facility.

Pallet Racking Installation

Space optimization is essential to any customer who needs inventory stored in the most efficient way possible. Pallet rack systems are one of the best ways to maximize the space in your warehouse or distribution center. Whether you need to install a new system or add to an existing one, American Material Handling has the expertise and equipment to get the job done. Experienced installation crews are essential for pallet rack installation to ensure safety, space optimization, and integrity of the pallet rack structure. When you choose AMH, we use industry-proven standards to manufacture pallet racks to fit your exact requirements. In addition, we can handle both standard and custom racking layouts, so regardless of the size of your project, our experts will have you up and running as soon as possible.

Design and Layout Services

At AMH, we have an in-house CAD design team that can help you layout pallet racks in your warehouse to maximize storage capacity. Using our cost per pallet position analysis can even help you and your real estate broker with site selection. Ceiling height, column spacing, lighting, code, and aisle spacing can significantly affect storage capacity and efficiency. Our award-winning designers will help you improve the flow of materials in your facility to ensure that employees move products as efficiently as possible. Our design team can also help you save money by avoiding wasted space in your warehouse. This puts your employees, customers, and products in a position to succeed.

Pallet Rack Repair

American Material Handling offers the best pallet rack repair. We can provide you with the solutions for fixing or repairing your damaged pallet rack. AMH provides customers with the expertise needed for restoring racking to full capacity. You do not need to fully replace your racking system, as our skilled team can often replace or repair your pallet racking system. Our focus is to keep your pallet racking system running smoothly. We go out of our way to do the best job possible, and we will work hard to make sure your pallet racks are ready to use as soon as possible.

RACKCYCLE
Repurpose. Repair. Reuse

At American Material Handling, we offer comprehensive solutions for pallet rack repair with RACKCYCLE products and services. RACKCYCLE emphasizes sustainability, aiming for the repurposing and reusing of damaged pallet racks while maintaining structural integrity, minimizing warehouse costs, and reducing operational disruptions typically caused from used pallet racks. Engineered and manufactured to exceed the strength of the original pallet rack, these customized repair kits come in various punch styles and colors to seamlessly match existing installations. With a large inventory readily available, we ensure quick installations by experienced local crews, with 48-hour emergency repair services available within a 300-mile radius of the Memphis area. Each repair kit typically takes between 20 to 30 minutes to install, keeping warehouse operations running smoothly.