Pallet Racking & Accessories

Pallet racks are the most widespread storage system in warehouses that stock palletized goods. This is due to their versatility, simple construction, easy assembly, and relatively low cost. Moreover, this pallet rack system is the only one that offers direct access to every pallet stored, ensuring efficient inventory management. This makes roll-formed pallet racks the perfect solution for companies that handle many SKUs and few pallets of each.

The main advantage of pallet racks lies in direct access to each pallet stored. This ensures maximum agility in loading and unloading operations and efficient inventory management. Similarly, this system’s versatility and the large number of storage locations it provides make it the ideal solution for multiple storage needs.

However, the choice of these racks may limit storage capacity in certain circumstances, particularly when dealing with few SKUs and many pallets per each. In this case, high-density storage solutions are generally recommended. Examples include drive-in/drive-through pallet racking systems, pallet flow racks, push-back pallet racking, and the Pallet Shuttle system.

Pallet racks can be customized to fit the needs of any warehouse. Rack heights typically range from 4' to 40', and for automated systems, they can go as high as 148'. There is no limit to the length, as racking bays can be connected one after another.

However, it is important to maintain safety by leaving enough room for passageways, and tunnel bays can be added for shortcuts between aisles. The depth of the racking frame is usually based on the size of the pallet. For example, for a standard GMA pallet that’s 48" deep, the frame is typically 42" deep.

The length of pallet rack beams is subject to the type of pallet stored. For instance, using 40" wide GMA pallets, beam dimensions can be 48", 96", or 144" based on the number of pallets wide on the level.

The endplate that joins the beam and upright post features a built-in safety locking mechanism designed to make the structure even safer. Since it forms part of the endplate itself, the mechanism is always activated. Once in place, it cannot be removed without completely dismantling the beam. This prevents accidental or deliberate manipulation, ensuring the strength and stability of the racking. The safety locking mechanism is an exclusive innovation of Interlake Mecalux.

While primarily used for pallet storage, pallet racks can be adapted through various accessories to accommodate other types of loads, such as containers (metal, plastic, and wood), reels, drums, and other cylindrical items. They can also house different medium-sized and large unpalletized products.

In the standard configuration, pallet racking does not use shelves, as pallets are stored directly on the beams. However, it is possible to place metal or chipboard shelves on the beams. This will adapt the racks to house other types of unit loads and enable additional operations, such as order picking directly from the racking.

Yes, pallet racks are compatible with order picking, allowing for both storage functions and picking tasks. One option is to perform order picking directly from the pallets located at floor level. This is a common practice in many warehouses. Likewise, it is possible to allocate the first two or three levels of the racking to order picking directly from pallets. This strategy can be implemented provided that the location heights are appropriate and operators can access the products easily (assisted, for example, by an order picker). Another alternative is to place picking shelves on the lower levels. This makes it possible to store other types of unit loads while housing reserve pallets on the upper racking levels.

Any type of forklift can be used (counterbalanced, reach trucks, VNA trucks, etc.), as long as the aisle has the appropriate width and the machines can reach the upper load levels. In the case of double-deep pallet racking, the forklift employed must have telescopic forks to reach the pallet furthest away.

When using VNA trucks — typically employed in narrow aisles with high-bay pallet racking — a guidance system is installed to direct the forklift’s path within the working aisle. This system can be mechanically guided, using profiles fitted to both sides of the aisle and anchored to the floor. Alternatively, it can be wire-guided, whereby a wire is embedded into the floor, producing a magnetic field to direct the forklift’s movement.

In warehouses using VNA trucks, pallet racking with a height of up to 40' can be easily automated, without altering the structure of the storage system. This is achieved by installing automatic trilateral stacker cranes. This solution, equipped with a trilateral extraction system, fully automates storage and retrieval operations. For complete automation of pallet storage, Interlake Mecalux provides support in designing and implementing an automated warehouse.