Pallet racking is one of our most popular products. And no wonder - the transport of goods on pallets is the basis of European industry, so warehouses must also be adapted to this. This has many advantages - above all, far-reaching standardization. Unfortunately, the pallets themselves are not always exactly made, so the racks for their storage must be prepared for their defects and damage, and at the same time allow for quick loading and unloading. Plus they have to be impact-resistant for forklifts in a busy warehouse and withstand enormous loads.
For these reasons, when designing our system Pal Rack®, we used the latest technologies. A team of experienced engineers, specialized software and many hours spent on static calculations. All this to be absolutely sure that the created solutions will be optimal. All components then passed exhaustive laboratory testing and certification. In this way, we have created top-class pallet racks that allow you to use the potential of the warehouse and enable effective work.
Construction of pallet racks
Our pallet racks meet the strict FEM (Fédération Européenne de la Manutention) requirements. However, the most important thing for us was to obtain an easy-to-use system that can withstand heavy loads, and at the same time will be resistant to damage. In the event of destruction of individual components by a forklift truck repair is quick and inexpensive. This is due to the modular design. It also allows you to easily modify the racks and adapt them to changing needs. But how are the Pal Rack® pallet racks actually built?
Pallet racks - frames
The frames consist of two columns and braces. The number of bracings depends on the height of the rack and the expected loads. The frame elements are bolted together, which reduces costs in the event of damage and facilitates repair. Each of these connections is secured with a self-locking nut. The variety of frames makes it possible to optimize the design and achievement up to 30 m high and the load capacity of spans up to 45 tons.
Pallet racks - end catch
Unlike the frame members, the beams are fastened without screws. This is possible thanks to a special connector made of high-strength carbon steel. The beam is simply inserted from the top and secured with a special clip to prevent it from accidentally slipping out. Thanks to this, the assembly is extremely fast, and the change of the height at which the beam is mounted takes place in a few moments. This allows for easy, self fit rack to current needs.
Pallet racking beams
To ensure a wide range of possible structures, we offer four types of beams load-bearing. Each of them has different properties, but they are united by precision of workmanship and high durability. Like the frames, the beams are powder coated, which protects them against corrosion as well as abrasions and impacts. Additionally, they are available in many sizes.
- Cold-formed hollow beam. The section of this hollow beam is reinforced at the top and bottom to prevent local damage when loading heavy pallets. Available in widths from 60 to 125 mm.
- A beam composed of two C profiles. The beam consists of two cold-formed C-profiles which together form a closed profile. It is highly torsion-resistant and provides high vertical and horizontal stiffness. Its load capacity is up to 4.8 tons per beam level. It is available in widths from 110 to 160 mm.
- Beams for shelf levels (picking). Light beam with an integrated connector. This beam has a standard edge for shelves and 28 mm thick panels. Perfect for storing light loads.
- Heavy Duty Beam. A beam composed of two C-profiles with an L-profile welded below the edge to support the chipboard. The shelves are flush with the upper edge of the beam. It's a choice for really tough jobs.
Delivery and acceptance level
P&D, or delivery and reception levels, are simply places for storing pallets, mounted on the extreme elements of the rack's frame. By installing them, you will increase the capacity of the rack while keeping the width of the working aisle unchanged. They can be equipped with a centering element, so that pallets can be stacked quickly and accurately.
Methods of reinforcing pallet racks
Our pallet racks can reach up to 30 meters in height, but even more common structures require stiffening. The basic method of strengthening is the installation of braces. In the case of narrow single racks, a gable connection to an adjacent double rack is used.
Pallet racks - bracings
Bracing of the rack structure is intended to increase the loading capacity of the racks. In some installations they are necessary to ensure the stability of the structure. The vertical brace (also known as the back brace) is located at the rear of the rack. It works in the vertical plane. The horizontal braces are installed between two beams, which gives the whole stability in the horizontal plane. Thanks to this relatively simple solution, the load-bearing capacity and durability of the pallet racks are significantly increased.
It happens that a single rack is too narrow to be sufficiently stiffened with bracings. In such cases, it is connected to the nearest double rack with a top fastener. The attachment is placed on the extended front posts of the frame. In the case of automated shelving, the gable clamp is also used to support the upper guide rail of the stacker crane.
Pallet racks with narrow aisles
This is an option for those who want to improve their work and introduce system solutions. It needs to be used VPN trucks. These trolleys will be led along a narrow working aisle, significantly facilitating the operator's work and reducing the risk of an accident. For this purpose, inductive guidance is used more and more often in place of a traditional rail one.
We design the racks and the guidance system taking into account a specific trolley, adjusting them to its dimensions and capabilities. Keep in mind that the low profile guide rails allow the pallet to be placed directly on the floor, while the higher profile guide rails require an additional “zero” beam level at the bottom. Pallet racks with narrow aisles are a great solution that allows you to maintain exemplary order and increase work efficiency!
QUESTIONS AND ANSWERS
more about pallet racks
The bookcase consists of frames and beams.
The frame is made of 2 poles connected with diagonal braces, which, after twisting, are anchored to the ground. The system is completed with beams (2 as standard) and they constitute the beam level.
The standard depth of the racks of 1100 mm allows you to store pallets with a depth of 1200 mm, but the depth of the racks can be adapted to other dimensions of the pallets. for storing chipboard with dimensions of 2800x2070mm, we use 1900mm deep racks, where the frame consists of 3 columns and the beam level is made of 3 beams.
Yes, the frame posts have perforation every 50mm, which allows the beams to be clipped lower or higher. Remember to keep the appropriate working height between the beam levels for trolley work when stacking and retrieving pallets with goods.
We cannot store other forms of storage except pallets on shelves, but the shelves should be adjusted accordingly.
We have a number of accessories that allow the rack to be adapted to smaller packages, e.g. a mesh shelf, crossbars recessed under chipboard, crossbars placed on beams, wema grate.
For installation, a floor with a minimum height of 150 mm is required, made of concrete at least B25. The substrate should be suitable for transferring loads from the racking system with the goods.
No, the paving stones do not meet the requirements of the substrate for pallet racks.
The basis in each warehouse is the height of the hall and the lifting height for which we have or will have a trolley with which we will operate the system.
The frames do not have to be mounted under the roof itself, but lower by the height of the package on the highest beam level, because the last level can be mounted on the last perforation of the column.
You should think how we will arrange the pallets on the levels, whether they will all be of the same height and weight, as a rule, the heaviest packages are placed on the floor level and in the higher order, the lighter and lower. Thanks to this vision, it is possible to adjust the beams with the appropriate load to a given level.
The pallet rack has the widest and tallest frame in the storage systems available on the market. Thanks to a wide range of choice of length and load capacity of beams and columns, we can adjust the racks to any warehouse or hall.
Unfortunately, there are situations when the truck operator hits the rack column during loading, which is why steel and plastic fenders are available in our store.
The steel fender is mounted at the front leg of the frame and anchored to the ground to cover the lower part of the column, where the most frequent damage occurs.
There is also a polyethylene cover mounted on any section of the pole,
resistant to impacts and abrasions, and thanks to its construction, easy to install and remove.
RACKS FOR PALLETS
storage of goods on pallets