Pallet Racks Systems Defined

Pallet Racks & Pallet Racking Defined

A pallet rack, also referred to as “pallet racking,” is for stocking inventory that sits on pallets (or “skids”) that are stored in horizontal rows with multiple levels; pallet racks allow warehouse inventory to be stored more efficiently (called maximum storage density). The pallet racks link together to create a pallet rack system. Forklift trucks are usually required to place the loaded pallets onto the racks for storage because of their size and weight. Pallet racks are essential and ubiquitous to modern warehouses, retail centers, and other facilities.

Pallet Rack Components

A pallet rack has several structural components:

 1. Load beams (also called step beams or box beams).
 2. Step beams have a 1⅝” step along their edge on which to rest the horizontal support component.
 3. Box beams have no inset and have four flat sides like a box. Load beams typically clip into or bolt onto an upright frame column.
 4. Upright frame columns (also called upright columns or uprights). Upright columns vary according to steel thickness, load requirements, and styles. The most common upright column is produced by rolling metal into the shape of a three-sided, cornered post, and is called an open-back roll-formed column. Holes or slots run up and down the column at standard intervals so that horizontal crossbeams can be mounted into the upright columns with pallet supports.

 5. Pallet supports are bolts or clips that fit into the holes or slots in the upright and come in various styles. Three common support styles are hat channel, tec screw, and clip-in style.

 6. Wire decks are used as support platforms to distribute loads more evenly. 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. Wire decking is made in three different styles. Most wire mesh decking has U-shaped channel supports, also known as struts, to support the load. With 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.

 7. Footplates, also known as footpads, are at the base of columns and serve as anchors to give the rack more stability: bolts are inserted through the footpad’s anchor 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.

 8. 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.

 9. 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.

10. Diagonal braces and horizontal braces, also known as windows or supports, are often welded inside the upright to give the frame more rigidity and stability.

11. Wall ties may be used for further support if the uprights are arranged in a row along a wall.

12. 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, ductile iron casting, and other durable materials.

13. Guard rails are installed to increase protection for upright columns and for human safety when platforms or steps are attached to pallet racks.

Also See Pallet Rack Types and Pallet Rack Safety Precautions

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