Racking and warehouse storage

Storage racking or pallet racking is a racking system for storing materials and goods on pallets on several levels. The main purpose is the optimal use of vertical space within a certain base area.

Pallet racking is a safe and efficient instrument for storage and handling paperbacked, crated, and containerised goods and materials in a warehouse. Racking cannot be used to store and handle bulk materials unless they are appropriately packaged. Rack systems are commonly used in warehouses to provide optimum storage capacity on a minimum floor space, i.e. to increase storage density.  

The proper use of racking allows a warehouse to operate more efficiently by reducing the time it takes to process customer orders. Additionally, the use of pallet racking also reduces labour-intensive daily operations by making goods and materials easy to find within the warehouse.

There are no restrictions on the goods and materials that can be stored in pallet racking, as long as they are properly packed and secured - and do not exceed the load capacity of the storage structure. There are several types of pallet racks, with each type of racking varying in layout, construction, size and load tolerances. In conclusion choosing the right type of pallet rack system is crucial to ensure risk-free daily operations.

Basically, a pallet rack is a structure that allows goods and materials to be stored in horizontal rows (storage racks) across multiple levels. In its most basic form, storage racks are simply a series of heavy-duty shelves. Racking systems consist of a number of essential structural elements, including uprights and framework, horizontal or diagonal bracing, beams and, if necessary, shelves.

Capacity utilisation of racking systems is best accomplished with a Jungheinrich forklift truck or comparable truck, which is capable of picking packed goods, including self-contained pallets and materials from and placing them into the racking. Pallet racking offers many options when it comes to depth customisation, as the racking can be adjusted to accommodate special size loads. Also, the base area of pallet storage can be modified as needed. New racking rows can be added subsequently if the appropriate floor space is available. The height of the racking is scalable, but any changes in height must be within the safe load and height tolerances of the warehouse racking.

Pallet racking is probably the most widely used system for storing goods. For example, our pallet racking product range includes wide aisle and narrow aisle racking, also in galvanised versions. The racking beams are available as light or box profiles to cope with any load capacity. Our pallet racking is completely tailored to the needs of our customers and only goes into production after all requirements have been fully tested.

The assembly of storage racks (of any type) is a two-stage process. Every stage of assembly is crucial and must be carried out by qualified persons. The first stage of the assembly process involves preparation and analysis of the existing infrastructure. Our expert assemblers determine the safest and most efficient way to erect the chosen type of storage racking. The analysis is based on a number of variables such as the suitability of the ground, the use of the equipment and the warehouse, etc. Once the engineers give the green light for installation, the actual assembly of the racking can begin.

All rack systems must be erected and secured in accordance with our strict safety regulations. Construction begins with the frame. Frames are built from uprights, diagonals or horizontals and footplates. After erection, the rack frame is anchored to the floor with heavy duty dowels through holes in the footplate. The rack beams are the next step of the assembly. Rack beams are hooked into the hole pattern of the upright with hooks on the agrafe and then secured with a locking pin. The final step is to insert the shelves (usually wood or metal). Again, the type of shelf depends on the particular racking system.

Like any other industrial equipment, a racking system, when operated within the prescribed tolerances, provides the required level of safety for your staff and warehouse. When it comes to the safe use of storage racks, operators should always follow the safety instructions (operating manual) which are provided by us. Among other things, load labels provide essential information about the maximum load capacity of each component (this should never be exceeded), proper loading and unloading procedures for heavy or unwieldy loads, and the manner and type of material handling equipment with which the pallet racking should be operated.

Some pallet rack configurations allow picking tasks to be performed directly on the racking. In some cases, this is done in close proximity to mechanical handling equipment that is being used simultaneously. Strict compliance to operational safety guidelines is of the utmost importance to avoid accidents. To ensure adequate operational safety, pallet rack systems must be inspected and maintained on regular basis. Good maintenance practices based on periodic inspections identify and isolate any safety issues with the result that necessary repairs or modifications can be made without risk of accidents.

Generally, three types of damage can occur to a pallet rack: structural, chemical and superficial. Whether no damage or all three types are present in your pallet storage will depend on its age and location, as well as the nature of your business. With regular maintenance these problems can be fixed easily.

Impacts and bumps from vehicles, as well as overloading and misuse, can cause damage that affects the overall structure of the warehouse racking. Currently, there are several types of passive protection such as guardrails, shock absorbing barriers, etc. that can prevent the racking from damage. A sufficient number of strategically placed deflector corners and full-surface impact protection elements can provide an adequate level of security. In the event of damage, replacing the defective elements is the only way to resolve the situation.

Depending on the nature of your business, chemical damage may also be a factor. Spills or contact with acids and other corrosive substances will weaken certain elements of the storage racking structure. Chemical protection treatments are available for both metal and composite materials.

For some racking systems it is possible to change the configuration after assembly. The extent to which a pallet rack can be changed after mounting depends on the type of system and its size and height, as well as additional elements and/or accessories. We provide guidance on which modifications can be made by operators and which changes need to be added from our side. As always, the main concern is safety, therefore any structural modifications to the racking must be made within the prescribed tolerances.

In general, storage racks and beams tend to be movable in many racking systems. If you want to change the arrangement of supporting elements or add and move aisles in the structure, be sure to contact us. The changes may affect the load capacity. Adjusting the layout or configuration of your pallet rack is a good opportunity to carry out a thorough inspection of the components so you know where you stand in terms of daily operational safety.

The load capacity of a pallet rack depends on a variety of important factors, including the specific type of racking system. A calculation (within a few per cent) of how much load a particular warehouse racking system can support is made by us through the analysis of some components and the main parts of the racking. These include, for example, the size of the driveway, the type of beam profile (light or box), the actual profile depth, the size of the beam surface, the size of the rack frame, level height and the upright (vertical load). It is important to consider the load on the floor slab on which the rack is installed, as this will affect the weight that can be supported by the storage racking system. The general guidelines for safe load limits for standard pallet racking are based on the theoretical maximum load/weight per pair of beams, which is set at 4.8 tons. The standard load per pallet location (with euro pallet) is 1.5 tons.

Nowadays, three different types of pallet racking uprights are used:

• Standard uprights.
• Heavy duty uprights.

Each of these uprights is capable of withstanding different loads, with the heavy-duty upright being the strongest of the three. The load capacity is calculated and guaranteed by Jungheinrich at the start of the design phase. Some of our pallet racking systems can be modified for higher loads by using reinforced structural components.

In all cases a safe height is the right height. An estimate of how high storage racking should be can be derived by analysing the existing infrastructure, the type of racking system, the size and lift height of the vehicles, the load capacity of the racking system and the weight of the load units.

The physical height of the facility, along with the specific type of sprinkler system and other fire protection and control equipment attached to ceilings and roof structures, limits the racking system to a specific height. The size and lift height of the vehicles in the warehouse also limit the height of the racking, meaning that if it is too high, forklifts will not be able to reach the top tie. Standard (counterbalanced) forklift trucks can reach up to 7.5 metres, while high-rack stackers are able to operate at a height of 16.5 metres. The type of warehouse also determines the height of the racking. Frequently used heavy or irregularly sized loads are better located at the bottom, reducing the need for height. The floor loading capacity of the facility also plays an important role in determining the safe and proper height of the racking storage.

Mobile racking is one of the smartest and most efficient racking systems in use today. As the name already says, this racking configuration is mobile. The main purpose of mobile racking is to increase storage capacity by reducing space requirements. Mobile racking is also called motorised pallet racking. The general consensus is that well-designed mobile racking solutions can increase storage capacity by 90 % for the same floor space.

Mobile racking "creates" additional storage space by turning aisles into productive storage space. In simplified terms, mobile racking can be clustered in blocks (no space between aisles) and divided into aisles when access is needed. Mobile racks move on wheels along rails in the floor, much like a rail car moves on rails. The racks move sideways along the rails. The racking system is perfect for high selectivity in dense warehouse environments.

Drive-in (also referred to as drive-through in some cases) is a pallet racking system that provides direct forklift access into the racking aisles. Whether it is a drive-in or drive-through system depends on the presence of an exit at the other end of each aisle. A drive-in pallet rack system typically uses the LIFO (FILO) (last-in-first-out or first-in-last-out) principle.

A drive-through pallet racking system uses the FIFO (first-in-first-out) principle because it has an input and an output at both ends. These racking solutions allow full use of available space, as they can have a standard height of up to eleven metres. When using drive-in or drive-through racking, it is advisable to use guide rails for safe operation of the warehouse racking.

No special equipment is required for the efficient use of this type of pallet rack system. Drive-in and drive-through racking can increase space utilization by 60 % to 80 % compared to standard pallet racking.

Push-back is one of the most space and time saving racking systems used today. A push-back pallet rack system optimises both floor space and storage space. This type of system provides easy access for any type of equipment. Push-back racking works in a clever way by stacking palletised goods one behind the other. Pallets can be pushed upward against gravity on inclined roller tracks. This means that the entire depth of the structure is exploited, resulting in a high degree of space utilisation.

Push-back racking allows up to five pallets to be stored one behind the other, depending on their weight. When operators remove one or more pallets from a given channel, the remaining pallets roll forward (by gravity). Push-back racking uses the LIFO principle because it does not provide direct access to pallets located behind the first pallet in the channel. This system is used only for storing whole pallets. It has an average fill level of approximately 85 %.

The use of the right forklift truck for your warehouse racking system is essential for safe and efficient operation. Forklifts typically fall into three main categories:

• Fuel type.
• Load capacity.
• Lift height.

Choosing a suitable forklift for your business is a matter of economics and practicality. As for fuel type, forklifts can run on gas or electric. There are also heavy-duty diesel forklifts, although these are mostly used in seaports and container terminals as they are much larger and stronger.

The most common types of forklift trucks are counterbalance forklift trucks, reach trucks, high-rack stackers and the pedestrian/passenger forklift. Which one you choose depends on the needs of your business. Each of these trucks has its own advantages and special features. Operating and maintenance costs should also be considered when making your decision. The lift height of the forklift truck is essential for its effective use; the lift height of your trucks should match the height of your pallet racking system. Jungheinrich will gladly support you in your choice.