Pallet Racking

The most common style of pallet rack, selective pallet rack, is designed for high-density warehouses that store a large variety of products. Selective rack provides 100% access to all pallet positions at all times without having to move other pallets. Based on cost per position, selective rack is the least expensive type of pallet rack. Selective rack is easy to install and easy to reconfigure should storage requirements change. While not as durable as structural steel pallet racking, rack safety equipment such as column protectors & guardrails can augment a rack’s durability.

Drive-In Pallet Rack is a narrow aisle storage system best suited for applications that utilize the Last-In, First Out (LIFO) method of inventory control. Pallets are stored back-to-back which creates a dense storage area. Drive-in rack is ideal for high-volume, low-SKU, & low product turnover applications.

Pushback pallet racking, much like drive-in rack, utilizes the LIFO method of inventory control. Pallets are stored on carts which move along rails. Unlike selective rack, which stores in a single pallet deep system, push-back racks often store pallets 2-5 deep, sometimes even more. When the first skid or pallet is picked, material behind gently rolls forward on rails. All levels are accessible individually to maximize accessibility.

Pallet flow racking is a combination of elevated rails, wheels, and rollers integrated into a racking system to provide gravity-assisted product flow within your rack. Using First In, First Out (FIFO) inventory control, this style of racking eliminates forklift travel within the racking system, increasing product accessibility and providing a high-density racking system in a compact footprint.

Warehouses with minimal space are ideal for pallet flow rack, as aisle space can be reduced by as much as 75%!

Industrial shelving is intended for non-palletized products, cartons, parts, tools, or other materials that will be loaded and picked by hand. These shelving units can be free-standing or bolted together. Pallet racks are heavy duty storage racks found in warehouses and big-box retailers such as Home Depot, Lowes, or Costco. Product is stored on pallets and loaded with a forklift or other powered industrial truck. Pallet rack is taller, wider, more durable, and higher capacity than shelving.

The most common height for pallet rack frames is 16′. However, we have frames available from 8′ all the way to 60′ high. Depths range from 18″-72″, with a 48″D frame accommodating most standard pallets, thereby being the most popular pallet rack depth. Pallet rack beams range in length from 4′ to 16′, with most common beams being between 8′ and 12′ long to accommodate 2 or 3 pallets per bay.

Pallet supports are used to reinforce a pallet rack system. Supports are installed inside the step of the crossbeams to provide extra stability for worry-free storage of heavy pallets. ASI recommends the use of two pallet supports per pallet position; They’re the best insurance you’ll ever purchase!

Pallet rack column protectors are one of a variety of rack safety products designed to reduce the harm done by forklift impacts and other equipment collisions to your racking system. A serious forklift accident can cause catastrophic failure of your racking system. Outfitting your pallet rack with safety equipment such as column protectors, wall ties, and aisle guards protects your employees, product, and storage investment from serious harm. ASI recommends that every rack system be outfitted with column protectors to maximize workplace safety. Column protectors are available in 1 foot increments including 12″, 24″, 36″, and 48″ column protectors.

There are three common styles of wire decking for pallet racks…

1. Waterfall Wire Decking is the most popular style of wire deck. Also called Step Channel Wire Decks, this type of decking features a “waterfall” wrapping around the top of the beam for added stability while a U-shaped support channel rests inside the step of the beam.
2. Flared Channel Wire Decking fits similar to standard waterfall decking. However, instead of the support channel resting inside the step of the beam, the end of the channel flares up over the top of the beam, further spreading the overall supported surface area. They are ideal for structural channel beams or box beams due to their universal design, but are also compatible with popular step beams.
3. Instep Flush Wire Decking sits directly inside the step of the beam with no overhang around the front face. The major advantage of this style of wire deck is unobstructed visibility of identification labels on the front face of the beam.

American Surplus recommends that particle board or plywood decking should be avoided in most cases in favor of wire decking or an open-faced decking system such as PunchDeck. This is for a few reasons…

1. Fire Safety: Plywood and Particle Board Decking isn’t just flammable; As a closed face decking material, wood decking prevents your sprinkler system from fully penetrating your racking in an emergency; Allowing a fire to spread further and faster. This double fire hazard means that fire codes in many municipalities outright ban the use of plywood or particle board decking in pallet rack systems.
2. Reduced Capacity: Plywood and Particle Board Decking does not support as much weight as purpose-built wire mesh decking or PunchDeck. Wood decking should only be used in light-duty pallet racking to prevent failure of the decking which could result in injury or damage to products.
3. Reduced Lifespan: Plywood and Particle Board Decking degrade far more quickly than the corrosion-resistant materials used in wire decking or punchdeck. Repeated impacts, exposure to moisture, temperature swings, and other environmental factors negatively affect the longevity of wood decking, leading to frequent upkeep & replacement to maintain your racking system’s overall safety.

Pallet rack row spacers enforce a consistent amount of distance between two rows (aka runs) of pallet rack. Row spacers have a flange on each end which secures the spacer to the frame. Row spacers should be installed when there are multiple rows of continuous bays installed back-to-back to ensure the parallel installation of the racking, as well as to improve stability of the overall system. The recommended number of row spacers is as follows:

• 4′-14′ High Pallet Racking: 1 Row Spacer Per Pair of Pallet Rack Rows
• 15′-24′ High Pallet Racking: 2 Row Spacers Per Pair of Pallet Rack Rows
• 25′-34′ High Pallet Racking: 3 Row Spacers Per Pair of Pallet Rack Rows

Pallet rack wall ties are one of a variety of rack safety products designed to maximize the stability of your pallet rack. Wall ties are designed to transfer forces from a rack system into a neighboring structural wall, playing a key role in preventing catastrophic incidents such as rack collapse, toppling, or displacement due to heavy loads, lateral forces, lift truck impacts, or seismic events. Outfitting your pallet rack with safety equipment such as wall ties, aisle guards, and column protectors safeguards your employees, product, and rack investment from serious harm.

Not every racking system necessarily requires wall ties. Their necessity depends on factors including rack height, load capacity, proximity to walls and other racks, and local regulations. Of course, the peace of mind that comes with the added stability pallet rack wall ties offer makes them well worth the investment.

Pallet rack netting is a rack safety product used to protect your employees and your inventory. Rack netting is hung underneath a pallet rack system, preventing product that has fallen off the racks from making it all the way to ground. This protects your employees from potentially deadly falling products, and protects your inventory from shrinkage due to fall damage. Not every racking system requires safety netting depending on height, product weights, and local regulations; But as an inexpensive, effective safety measure it is well worth the small investment.

Yes, you should always anchor your pallet rack to the floor. The footplates on your uprights offer specific locations to place your anchors, which are essential to prevent the entire rack system from falling over as well as for enforcing uniform aisle spacing.

The first place to start is to know what you’ll be storing and where you’re storing it! Start by making a checklist and identifying the following details:

• What Dimensions Are Your Pallets? (WxDxH)
• How Much Does Your Product Weigh?
• Is Your Inventory Perishable? Do You Have Other Inventory Control Concerns?
• How Much Space Will Your Pallet Rack Have? What Are The Overall Dimensions?
• Are There Columns Or Sprinklers Obstructing The Floor Plan / Vertical Space?

Once you know these basic details, you’re ready to call a rack specialist at American Surplus who can assist you in designing the right racking system for your application. A great storage system flows seamlessly with the rest of your business process, and we’re are here to help just a phone call away at (800) 876-3736!

Yes, our Racking Department and State-of-the-Art Automated Beam Fabrication Shop can customize, cut, and weld racking to meet your needs. To get started, get in touch with our rack specialists at (800) 876-3736 or request a free pallet rack consultation online!