Getting the Load Right for your Pushback Rack

pushback rack applicaiton

Push back rack systems are excellent high density storage solutions — perhaps the most economical way to squeeze space out of a crowded warehouse.  All loads are stored and retrieved from the same aisle. This reduces the number of aisles needed in a facility, freeing up more space for storage. Aisles can take a great deal of space up in a typical warehouse, so by implementing a pushback pallet rack system, you essentially swap selectivity for space. Push back rack systems provide a Last-In-First-Out (LIFO) inventory rotation, so you have to be certain your load fits. If it does, congratulations — you’ve just saved a lot of space. But there are issues that can arise when pushback rack is inappropriately specified or utilized. Here are some of those…

Using Incorrect Pallets

Once a push back system is installed, it’s  critical to be sure you use the right pallets. It’s very important to know the type and size of pallet the rack was designed to store. Push back systems are designed to handle pallets and loads of a particular size and weight. For example, if your push back cart was designed to use 40” wide by 48″ deep pallets, do not use pallets that are longer or shorter than this size.

pallet sizes are critical for loading into pushback rack

Using pallets that were not designed to be loaded into the system can lead to:

  • Cross Stacking (a pallet is resting on two different carts); this will cause a jam or potentially damage the carts, your load, or both
  • improperly loaded palletsUnder utilization of the systems full capacity
  • Damage to the cart system and possible damage to the product being stored
  • In general, pallets should be GMA style pallets, with at least five (5) bottom boards running left-to-right.
  • Defective or damaged pallets may not allow the push back system to operate correctly
  • Pallets should also be shrink-wrapped or securely banded before you place them in a system
  • Loads shouldn’t overhang the pallet on any side, including slip sheets, shrink wrap, carton flaps, improperly stacked boxes, etc.
  • Overhanging loads are almost guaranteed to cause the cart to hang up and your system to jam. Worse yet, they can be a safety hazard as items fall out of the rack.

Loading Capacity Consistency

pushback rack load lanesPushback racks are about uniformity — of load type, pallet type, and load weight. Pallet load weights, in a single push back lane, should not vary by more than 500 pounds, even if the rack can accommodate the weight of heavier pallets. Don’t store a 2,000-pound load in the same push back lane as a 1,000-pound load.

Similarly, push back rack systems are not intended to be used for applications where the aisle-side pallet is “picked.” Removing cartons reduces the load weight of the last pallet in the rack and may cause the inside pallets to push the aisle pallet out of the rack. Loading pallets of varying weights within the same lane may cause the heavier loads to push the lighter loads out of the rack. That means product damage, injuries, or worse. Be consistent with your loads. They should be alike in as many ways as possible for pushback rack to work correctly and safely.

Bottom line: If you have pallet loads that vary by 500 pounds or more, designate push back lanes to handle common load weights.

Most rack manufacturers have extensive usage guides. These tips are general guidelines, but you should always refer to your rack manufacturer for exact tolerances and specific specifications. If you can’t find the manual that came with your rack, many websites will have them in PDF form. You can also call the manufacturer or even a distributor like Cisco-Eagle for help hunting one down.

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Scott Stone Cisco-Eagle's Director of Marketing. He has over 25 years of experience in the industry.