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Some Tips On Developing A Warehouse Rack Layout

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Developing a warehouse rack layout requires a balance of safety, space management, and accessibility. Each level of the rack must be sturdy enough to support the materials stored on its surface. This, in turn, will stabilize the entire system so as to protect both property and personnel from the dangers of collapse. The system must also efficiently utilize the vertical cube in order to avoid consuming the entire floor of the facility. Fork trucks must be able to access pallets without risk of collision or injury to pedestrian personnel.

In every warehouse rack layout, the most important piece of information is the height and depth of the pallet racking uprights. This is critical to providing proper support to the materials being stored. Racks can hold anywhere from 1,000 to 6,000 pounds per level.

To calculate the dimensions of your uprights, start with the heaviest load you plan to store on the system. Record the height and width of each loaded pallet. Then, weigh the unit and base your estimated load capacity on the heaviest pallets in your facility. Next, determine how tall the entire system will need to be. The height of each upright will be approximately 6” more than that the height of your total pallet loads. This extra space provides plenty of clearance for pallets being loaded and unloaded from the rack.

The next factor to consider for your warehouse rack layout will be the width of your cross beams. Multiply the weight of your heaviest palletized load by the number of pallets that you intend to store on each level. Beams that are taller are capable of bearing more weight. Cross beams are designed to support anywhere from 1,000 to 6,000 pounds each. If you are uncertain as to what dimensions of beams to purchase, please ask your Easy Rack account manager for assistance in determining the proper dimensions.

Typically, the calculation of pallet rack uprights and cross beams requires only basic mathematics. This is seldom the most difficult element of the average warehouse rack layout. In most facilities, only a portion of the floor plan can be dedicated to pallet racks. Utilizing space wisely without overcrowding the facility is frequently the most challenging task that the facility manager faces.

While there are 12-15 different types of pallet racking systems, we have found that 9 out of 10 facilities are looking for the Tear Drop style. These racks are easy to assemble and adjust without tools, making them adaptable to a wide range of applications.

In most cases, pallet racking can be installed along one of the walls in the building, leaving the rest of the facility to other purposes. However, there are some buildings that may need to devote their entire space to racking. If this is the case, Easy Rack will examine the floor plan of the building and develop a warehouse rack layout that best accommodates the process flow of the organization. Aisles can be constructed wide enough for one or two forklifts with enough space on either side to ensure the safety of personnel walking through the aisles.




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