Pallet racking
Pallet Racking is more complex than it appears, and no two systems are the same. Many factors must be considered to design safe Pallet Racking optimal for your warehouse, such as load capacities, pallet type, pick rate and type, inventory level, regulatory standards, seismic zoning, building footprint, and more. Read below to learn more about how these elements determine what Pallet Racking suits your facility.
With over 40 years of experience designing custom Pallet Racking for all types of warehouse operations, you can count on Madzo to ensure every variable and need is accounted for. Contact us today for a free quote.
pallet racking systems
selective
The most common system, Selective Racking consists of single-deep rows that provide full access to palletized loads from the aisle, allowing easy storage and retrieval.
This racking best suits multi-SKU inventories with low pallet counts per SKU, and does not require specialized lift trucks to utilize.
Selective is ideal for order picking operations and is highly compatible with Carton Flow systems.
Pallet Movement: pallet in, pallet/case out.
drive-in
With the ability to be configured up to ten-deep or more under certain conditions, Drive-In Racking achieves extremely high storage density.
Drive-In consists of angled rails that support the edges of pallets. Forklift operators drive into the system, between the angled rails to load and unload pallets.
Drive-In is only suitable for low-SKU inventories with very high pallet counts. Inventory and stock rotation must be carefully considered before implementing this system. Specialized lift trucks are not required to utilize this system.
Pallet movement: pallet in, pallet out.
double deep
As the name implies, Double Deep Racking consists of two-deep rows storing pallets consecutively.
Specialized "deep reach" lift trucks provide full access to to palletized loads from the aisle.
This racking is suitable for multi-SKU inventories with higher pallet counts per SKU than Selective Rack, but is not compatible with case picking.
Pallet movement: pallet in, pallet out.
push-back
Push-Back allows up to six deep pallet storage, with aisle access to every pick face. Push-Back operates with a series of nested rolling carts on lanes sloped towards the aisle.
Forklift operators place the first palletized load onto the cart. With the next palletized load, operators push the first pallet back to expose the next cart. To retrieve, the first pallet is removed from the cart, allowing the pallets behind to roll along the sloped lane towards the pick face.
Push Back allows storage of more SKU's than other systems, with standard lift trucks.
Pallet movement: first in, last out (FILO).
narrow aisle (vna)
Similar to Selective, VNA Racking consists of single-deep rows that provide access to all palletized loads from the aisle.
Compact "man up" and "man down" forklifts specifically designed for VNA allow dense row placement, optimizing floor space to provide high storage capability.
VNA suits multi-SKU inventories with low pallet counts per SKU, and is compatible with Carton Flow systems for case picking.
Pallet Movement: pallet in, pallet out.
Cantilever
Cantilever Racking is designed for the storage of bulky or long items such as lumber, pipe, tubing and more.
This racking can be single or double faced, consisting of upright columns with braces and support arms. These components are fabricated to support a wide range of load capacity weights and product sizes.
Cantilever can be stored outside or indoors, with manual or automatic handling.
roll formed vs structural
Roll Formed and Structural are the two types of frames used in Pallet Racking, named after the production technique used to make them. For Roll Formed, coils of light gauge steel go through a forming machine that gives it it's desired shape and required holes, which determine its load carrying capacities. Structural Racking is made from hot-rolled steel formed in a mill under high temperatures. These standard mill-produced shapes are C-Channel, I-Beam and Angled. Structural Racking relies on shape and thickness to determine load capacity.​
Benefits of Roll Formed Racking: low production and installation costs, easily reconfigurable as it does not require bolted beam connections, durable powdercoated paint finish, and works well with high density storage.
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Disadvantages of Roll Formed Racking: easily damaged due to light gauge steel, and damaged components require immediate replacement.​
Benefits of Structural Racking: highly durable and capable of retaining some load bearing capacity if damaged, higher load capacities, suits high traffic, harsh environments such as freezers or coolers.
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Disadvantages of Structural Racking: approximately 20% higher fabrication costs than Roll Formed, and is more costly and time consuming to install due to bolted beam connections and weight.