Pallet racks are probably the most common warehouse storage equipment in the world, and for good reason: they’re safe, versatile and use the vertical cube of high-bay warehouses when correctly specified, loaded, unloaded and used within the rack’s tolerance. Load distribution–the way a load sits on your racks–is a critical factor for safe usage. Here’s how to get it right.

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Traffic coming and going within your facility’s pallet rack storage areas is a daily occurrence (or at least it better be!) and the higher the traffic, the better off your operations are probably doing. With tight supply chains, inventory shortages, longer lead times and limited patience from customers, movement around your rack is a constant. You can’t afford an accident. With that constant activity comes the potential for rack and inventory damage from various angles and situations. With that in mind, what are some simple ways you can protect your pallet rack?

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Above – left to right: reinforced resin wheels. split rollers, full-width rollers, steel skatewheels. Each roller type has advantages in terms of versatility and capacity, depending on your load and environment.

Pallet flow rack is one of the most space-efficient, first-in, first-out high-density pallet storage and picking systems available. Because the first pallet stored in a flow lane is always the first pallet picked at the front, you constantly rotate inventory. It’s a simple concept but the execution can be complex based on the load size, weight and other characteristics. One of the most important decisions is the type and style of roller needed.

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Racks will often be damaged over a long lifetime of use. When you see a bent beam, out-of-square beam, damaged upright or other issues with your pallet racks, you can’t ignore it.

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Pictured: Cisco-Eagle VP of Sales James Murphy and Senior Project Manager Larry Victory

Two of our leading manufacturer partners, WireCrafters and Steel King recently awarded Cisco-Eagle for outstanding performance in 2020.

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The nature of pallet racks—adjustable beams and teardrop connections on uprights—invites reconfiguration. Many rack manufacturers’ beams easily connect to other manufacturers’ teardrop uprights, which lets you mix & match components. This versatility can invite trouble if all the factors aren’t considered. Before you adjust beams, add new loads or reconfigure your racks, consider all the factors.

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I’ve become an expert in the shifting soil beneath my house over the years. With most of my area enriched with clay soil, I have gotten to know and understand the subtle shifts that occur in my foundation for each season. There have been areas of concern and repairs to make as my foundation has shifted over the years. It’s something we just have to deal with.

Your warehouse covers a much larger area than my one-story home, but regardless of how much foundation you have, you want to make sure your floor can handle the shifts and carry the weight it holds.

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One of the critical aspects of pallet rack system design, aside from the specs of the rack itself, are the various clearances between rack components, the loads and the surrounding environment. Flue space can be critical for fire safety compliance. Space between a rack row and the row behind it can contribute to a safer and more effective rack system. Narrow aisles can contribute to accidents. Too tall? You could cause damaged and falling inventory, as well as damage to fixtures or HVAC components.

At the end of the day, the space around the rack is nearly as important as the rack itself.

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Buffers can be found in most warehouses and manufacturing facilities, and they take many forms. You can build buffers into racks, floor space, conveyors or external storage areas like truck trailers. When you need to temporarily store materials before they enter putaway, shipment, kitting, processing, or another production process, what are some of the best design, equipment specification and usage practices?

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Pallet racks are safe and stable storage for pallets and bulk loads in warehouses, factories and other facilities, but you should be aware of the kind of dangers they pose when misapplied, modified or neglected. In any safety program, you’re always looking for risks you can prevent. What are some avoidable risks when it comes to pallet rack?

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