One of the most versatile industrial warehouse storage solutions in the market, selective pallet racking lets businesses quickly sort through inventory without disrupting SKUs or other products. Its simplistic yet efficient design makes it one of the most common fixtures in any commercial warehouse, optimizing operations with minimal investment.
In this article, we’ll explore more about this renowned inventory management solution, along with a design and buying guide for any industry.
Components and Accessories of Selective Pallet Racks
Let’s start the discussion by dissecting the various components that make up a selective pallet rack. While these racks are highly customizable depending on warehousing needs, they have specific parts that help them complete their assigned tasks.
Main components of selective pallet racks would typically include the following:
Upright Frames
Every selective pallet rack has a couple of upright frames that determine its overall height and total load capacity. Made from either high-grade wood or metal, these vertical structures are joined by diagonal or horizontal bracings to give structure and stability to the pallet rack.
Beams
If upright frames dictate the height of the selective pallet rack, load beams are the horizontal bars that directly support the pallet’s total weight. These steel bars connect to the upright frames, forming the various shelving levels where products can be securely placed.
Base Plates / Footplates
Also referred to as anchors, the base plates are thick pieces of metal that are welded to the base of the upright frames. They are attached to the facility’s concrete floor using anchor bolts, preventing the rack from tipping and ensuring the structure is fully stable.
Safety Pins
To further secure the selective pallet rack from accidental dislodgement by forklifts, each horizontal beam is attached using small pins or clips. These safety pins can also provide additional support to the beam, improving its load-bearing capability.
With the selective pallet rack’s base completed, it’s time to configure the setup according to the specific task or intended load. These are where the accessories come in, which could provide the products with a stable surface to rest or protect the structure from damage. These can also allow the pallet racks to carry products with non-standard configurations.
As for selective pallet rack accessories, these would include:
Pallet Support Bars
Also called crossbars, these metal profiles are attached to the beams perpendicularly to keep the pallet rack stable and durable. It also lets the rack carry heavy or undersized pallets without adding stress to the structure.
Wire Mesh Decking
Typically made from high-grade metal, wire mesh decking gives a non-palletized product a solid and breathable surface to rest while preventing small items from falling. Depending on the product, these can also be used alongside water sprinklers to let water pass through the gaps.
Row Spacers
Installed between two back-to-back rows of racks, these metal row spaces keep the aisles uniformly spaced apart. This also provides additional stability to the selective pallet racks for carrying larger loads.
Upright Protectors
The stability of selective pallet racks relies heavily on their bases, which can be damaged when hit by forklifts moving across the facility. To prevent this, heavy-duty guards can be added on the rack’s base to both shield the columns and absorb the impact from incoming machinery.
Aisle-end Protectors
As the ends of selective pallet racks are exposed to vehicle traffic, they need added protection to avoid any damage to the racks or the products. Aisle-end protectors can be installed on the ends to ensure better resilience from bumps or impacts.
Factors in Selective Pallet Racking Design
While there’s nothing wrong with purchasing off-the-shelf selective pallet racks, it might not address all your storage needs. Ideally, the best shelving system for your facility should be custom-built from scratch, using relevant data based on the product dimensions, weight, and quantity. You also include other factors, like facility conditions and forklift types.
In this section, we’ll dive into several considerations when designing a custom selective pallet rack.
Determining Load Capacity & Beam Spans
First, it’s best to start by getting the total load capacity of the selective pallet rack, as well as the length of each horizontal beam.
Beam Length
To calculate the beam length based on the pallet’s dimensions, remember to include the total load width and the required safety clearances between the pallets and frames. As a standard, internal clearances should be broken down as follows:
- 3 inches between the first pallet and the left upright frame,
- 6 inches between each pallet, and
- 3 inches between the last pallet and the right upright frame.
You can use this basic formula:
Beam Length = (Load Width x No. of Pallets per Level) + Internal Clearances
So, for a beam that will hold 3 30-inch pallets, the computation will be:
Beam Length = (30” x 2) + (3” + 6” + 3”)
Beam Length = 60” + 12”
Beam Length = 72”
Do note that the measurement is from the inside of the first upright frame to the inside of the other, not including the connector brackets. Also, for high-traffic factories, it’s best to increase the side clearance from 3 inches to 4 to 5 inches to give the forklifts more room to move.
Maximum Load
Some points to look out for when computing the maximum load of the selective pallet rack:
Always do it in pairs, where the front and back beams are working together. Also note the UDL or Uniformly Distributed Load, wherein it is assumed that the weight is spread evenly on the beam.
Next, multiply the weight per level (heaviest pallet x no. of pallets per level) by the number of levels on the rack.
Factor in the beam deflection or (L/180 Rule). While beams are expected to bow when weight is introduced, it should be above a certain threshold to prevent failure. Follow the formula to get the maximum deflection limit:
Max Deflection = Beam Length / 180
Optimizing Aisle Width for Forklift Access
Next, determine the aisle width of the selective pallet rack that would perfectly accommodate the forklifts used in the facility. Specifically, consider striking a balance between the forklift’s turning radius capacity and operating speed as the aisle width is being configured.
- 12 to 14 feet is considered a Wide Aisle, which is the standard requirement for most counterbalance forklifts.
- 8 to 10 feet is called a Narrow Aisle, which can work for reach trucks and offer higher storage density.
- Going 5 to 6 feet can work as a Very Narrow Aisle, but would only work for specialized machinery like order pickers and turret trucks.
Vertical Space Utilization
Then, it’s time to consider how to maximize the vertical space available in the facility while keeping a safe clearance for forklifts and fire sprinkler heads. The formula for determining the ideal number will be:
Vertical Increment = (pallet height + product height) + (6” lift clearance) + (beam face height)
This formula accounts for the forklift’s maximum lifting height, so it can safely cover the top beam without hitting the ceiling or damaging the rack.
Seismic Design & Floor Slab Requirements
Floor Slabs
Another point of consideration in designing the selective pallet rack is how thick the floor slab should be. As the pallet rack carries a heavy load, which would be transferred to the floor, the slab is expected to withstand said pressure without breaking.
- For heavy-duty pallet racks, it’s best to have 7 to 8-inch reinforced slabs with a compressive strength of 4,000 PSI.
- It’s also recommended to have the slabs reinforced with steel rebars or mesh to prevent cracking.
Seismic Design
Some warehouse locations are prone to seismic activities; thus, the selective pallet racks must anticipate such events.
- Utilize larger seismic baseplates for better lateral force distribution, usually around 5” x 7” with a 3/8” thickness.
- Additionally, use two or more expansion bolts with a diameter of 3/4″ per baseplate to properly anchor the rack to the floor.
Single vs. Back-to-Back Rows
Depending on certain factors, you may opt to go with either a single row pallet rack or back-to-back rows for your setup. Each offers distinct advantages, such as:
Single Row
- Typically placed against walls or as perimeter racks
- Pallets are more accessible from a single aisle
- Easier to set up, though it requires wall ties for added stability
Back-to-Back Rows
- Utilized row spacers to connect the pallet racks
- Saves aisle space, as pallets are accessible from either side
- Higher storage density and better overall stability
Benefits of Selective Pallet Racking Systems
Now, let’s tackle the age-old question: “Why should you add selective pallet racks in your warehouse?” Simply put, it makes warehouse operations easier and faster while providing room for expansion. Here are three key perks businesses can achieve through the inclusion of selective pallet racking systems:
100% Selectivity
As each pallet can be easily accessed by forklifts at any time, it helps businesses optimize inventory flow without compromising product quality. This setup naturally complements the FIFO or First In, First Out inventory rotation, ensuring product goes in and out naturally.
Moreover, multiple selective pallet racks allow businesses to carry a large number of product types while maintaining the proper SKU count. SKUs can be easily tracked, thus making inventory management quicker in the process.
Cost-Effectiveness
Selective pallet racking systems are affordable to source, even if fully customized to suit specific warehouse operations. Each setup uses simple uprights and beams made from galvanized steel, with no complicated railing mechanisms or rollers typically found in complex systems.
Additionally, due to their simple construction, they are also quick and easy to set up in the warehouse. No specialized installation or training required to start using the pallet racks, saving on time and money.
Flexibility & Scalability
Then, there’s the flexibility of selective pallet racks that businesses can take advantage of. Beams can be adjusted according to pallet size requirements, allowing for quick and hassle-free adaptability with any product. Plus, there are several accessories that can be added to the pallet rack, expanding its usability.
Speaking of expansion, selective pallet racks can also be easily expanded as the business grows. From adding new bays to accommodate new inventory to reconfiguring the existing racks for a new warehouse, making changes based on operational demands is simple with this setup.
Applications of Selective Pallet Racks
Source: iStock
Selective pallet racking systems provide an efficient and easily expanded inventory management solution for various industries. Below are some markets where these setups can work best:
Retail and E-Commerce
In the fast-paced world of retail and e-commerce, having fast and easy access to products is paramount to optimal order fulfillment and customer satisfaction. Selective pallet racking systems fit perfectly in addressing this market’s need for simultaneous picking, as several employees can work on different aisles at once.
- Lower levels of the pallet rack are typically used for manual product picking.
- Upper levels are where bulk products are stored, ready for large orders.
3PL or General Warehousing
General warehousing or third-party logistics (3PL) companies offer product storage solutions, often catering to several clients at any given time. Selective pallet racks help this industry properly manage large inventories, as they can carry various pallet sizes and SKUs without the need to constantly revise their setups. This lets them adapt to any client, improving management capabilities and client satisfaction.
Производство
The manufacturing industry constantly deals with different parts and raw materials to create its products, often in large volumes and dimensions. The market not only needs a way to properly segregate the materials but also requires a sustainable method to quickly identify parts for faster production.
With selective pallet racking systems, any component can be stored securely, no matter the shape or size. The racks can also be modified to help store items not placed on pallets, like drum cradles or mesh racks.
Еда и напитки
Food and beverage products have strict expiration dates, meaning they should follow the First In, First Out flow to prevent recalls or other costly issues. With selective pallet racking systems, pallets are always within reach, thus the product can be shipped out accordingly. Also, they can be used in cold storage and freezers for factories with a high SKU variety.
How to Choose the Right Selective Pallet Racking Supplier?
Sourcing and designing a selective pallet racking system is one thing, but partnering with the right supplier makes a whole world of difference. With the right partner, your sourcing experience becomes smoother and easier, not to mention more value for your budget.
These are some things you should look for in a reliable selective pallet racking supplier:
Material Quality
Due to the simplicity of the selective pallet racks, the material quality plays a more important role in ensuring its load bearing and stability capabilities. Thus, your manufacturing partner must have access to the best materials to create your pallet racking system.
iWarehousing sources all its raw materials from the best suppliers in China and abroad, conducting strict inspections on all incoming materials to maintain quality levels.
Custom Design Capabilities
Understanding that not all facilities are the same, each selective pallet rack must be customized to suit industry operational requirements. From computing the proper dimensions for optimal load management and making the right adjustments to suit specific needs, your pallet rack maker must guide you effectively throughout the customization process.
As a seasoned storage rack manufacturer for more than 35 years, iWarehousing knows your market needs fully and designs your selective pallet racks to perfectly match your warehouse operations.
Safety Compliance
Part of a manufacturer’s task is to guarantee that your selective pallet racks meet industry safety standards per region. They conduct a series of inspections and tests, making sure they comply with local and international requirements.
iWarehousing takes pride in maintaining consistent quality control standards throughout our manufacturing process. Every step undergoes intensive inspection and testing, with an incoming material report available upon request.
Project Management & After-Sales Service
Outsourcing your project can be daunting, so having a reliable project manager on-site can help make the process smoother and more efficient. Not only does a project manager keep you updated with how the project is progressing, but they also address all your concerns quickly.
Working with iWarehousing means you’re assigned a dedicated project manager who acts as your eyes and ears throughout the project. You receive constant updates, along with prompt responses to your inquiries.
Elevate Your Business with Selective Pallet Racking Systems
Selective pallet racking isn’t just a storage option – it’s an ideal choice for warehouses of any scale or market. This setup lets businesses optimize their inventory management through a simple system that can be customized to their needs. Additionally, it’s relatively inexpensive and easily scalable, perfect for any industry.If you’re looking for an expert selective pallet racking manufacturer for your business, then your search ends with iWarehousing. We’re a globally renowned end-to-end warehouse racking maker with decades of experience and an unmatched range of services. Contact us today for your free consultation and see how we can fulfill your business requirements!
