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
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
Introduction
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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 : Property Analysis Cost Analysis Specialist Surveys Market Analysis Investment Appraisal Financial Viability Schematic Drawings 3D Imagery 3D Animation Design Brief Total Project Delivery Contacts : David Burke Mob : 07825 368086 david@industrialspacesolutions.co.uk Andrew Littler Mob : 07900 270023 andrew@industrialspacesolutions.co.uk