Pallet racking

Frame

A frame (or ladder) is a basic component of a pallet rack. This part consists of 2 upright profiles that are supported by a base plate. The uprights are connected to each other by a series of diagonal and horizontal C-profiles. The C-profiles give this component the appearance of a ladder, but at the same time provide stability.

Frames have different upright profiles depending on the requested capacity and configuration of the pallet racks. The depth and height of the frames also varies based on the desired configuration of your storage system. The frames will always be adapted to the specific requirements of your warehouse design.

Base plate

As mentioned before the base plates are part of the frame and as such are a basic component of the pallet rack as well. Without the base plates, a pallet rack cannot be anchored to the floor and therefore cannot remain standing erect. The base plates are connected to the frame using a series of bolts and nuts. These create a rigid connection between the frame and the base plate, the latter is in turn firmly anchored to the ground.

There are different types of base plates that each have their own area of application. The choice between plates depends first and foremost on the configuration of the storage system. But it is also possible to opt for another base plate if this is desirable for your specific warehouse design.

Beam

Beams are the last basic components of the classic pallet racking. Different frames rest stable on the ground thanks to their anchored base plates and are now connected by beams. These beams serve the ultimate purpose of the storage system; creating locations for the storage of goods.

Beams are usually placed in pairs; one at the front of the frame and one at the back. This fashions levelled surface on which a pallet can rest on both beams of the pair.

For the safe use of your storage system, beams are always provided with 2 safety pins. These are placed into specially provided holes on both ends of the beam. Thanks to an inventive turning system the beam can now no longer be accidentally lifted as the pins prevent this.

Beams are produced in a huge variety of sizes and types. The combination of the height of the beam, the type of construction and the steel thickness determines the capacity of the beam. The width is adapted to the type of goods you have to store in your warehouse.

P&D station

With certain storage systems it may be useful to equip the ends of the rows with special locations. These locations are also referred to as P&D locations after “Pick and Deposit”. P&D locations are created by special beams that run past the last frame. For stability, the beams are connected at their ends to each other using a profile.

P&D stations are mainly used for narrow aisle (VNA) solutions to allow the VNA machine to pick up pallets without having to leave the aisle. Beside the use in VNA aisles they can also be used in other warehouse setups.

Upright protection

There are several options to protect the basic components that ensure the stability of the pallet rack. However, the goal is always the same; reduce and/or stop the impact on the front of the frame.

The front of the frame is the part of the frame that is freely accessible in the aisles of the pallet racking system. It is therefore possible to hit it with the forklift (or other machine) used in these aisles.

You can use various free-standing protections to stop the impact. However, these must be anchored in to the ground. You can also make use of protections that are placed on the frame itself. The latter are made of plastic (clip on system) and metal (connection with bolts and nuts).

Lateral protection

Frames can be protected in the aisles of the pallet racking system with upright protection which prevent an impact on the front of the frame. However, on the end face of the rows, the entire side of the frame is exposed for contact with MHE. Using only upright protectors will not offer sufficient protection for these frames.

To protect the side of the frames you can utilize so-called lateral protection. These protections can consist of two upright protectors which are connected using one or more sturdy UPN profiles. But one can also opt for separate lateral protections which are not connected to the upright protection. These can be manufactured in plastic, wood or metal, depending on the requirements of your warehouse equipment.

VNA guiding profile

VNA (Very Narrow Aisle) is a warehouse solution where a pallet racking system uses very confined aisles. This setup provides a more compact storage system, but introduces new risks at the same time. The machines that use the narrow aisle have very little space to maneuver between the pallet racks.

By placing guide profiles in the aisle, the frames and machine are separated from each other. The machine can move freely through the aisle and will be kept in position by the guide profiles at all times. The profiles are firmly anchored to the ground to provide sufficient resistance to the machine exerting force.

To facilitate access to the corridor the guide profiles at the end of the aisle can be provided with a head piece. This head piece has a rounded shape which will automatically guide the machine straight in to the aisle.

Support profile for pallets

Pallet racking beams are configured in pairs to support the pallet equally on both beams. Between the two beams the pallet must be of sufficient quality to support its own weight. There may be cases where this is not possible, for example due to a huge variety of pallet sizes, poor pallet quality, special pallets that need extra support, etc.

When this is the case it is possible to opt for an extra connection between the beam pairs in the form of support profiles. For the storage of pallets flat top profiles are used. The profiles can be fixed to the beams using self-tapping screws. The number of profiles and the configuration will always be adapted according to the specific needs of your pallet racking and warehouse solution.

Support profile for containers

Pallet racking beams are configured in pairs to support the stored load equally on both beams. When storing containers (or “stillages”) it can be quite tricky to do this in a safe manner. Some containers have legs that do not fit or slip on the beams. The same problem arises when you need to store containers different sizes and depths.

When this is the case it is possible to opt for an extra connection between the beam pairs in the form of support profiles. For the storage of containers flat top profiles with an extended lip are used. This extended lip will guide the placement of the containers on the support profiles. The profiles can be fixed to the beams using self-tapping screws. The number of profiles and the configuration will always be adapted according to the specific needs of your pallet racking and warehouse solution.

Heightened support profile

Pallet racking beams are configured in pairs to support the stored load equally on both beams. When storing sizable goods which are not stored on pallets or inside containers it can be impossible for your MHE to drop off the load on the beams. In order to drop off goods straight form the MHE forks, you need to create a free space for the forks.

When this is the case it is possible to opt for an extra connection between the beam pairs in the form of heightened support profiles. For the storage of loose goods the profiles will have a heightened top. This heightened top creates the free space for the forks, by creating a ‘floating’ storage level for your goods. The profiles can be fixed to the beams using self-tapping screws. The number of profiles and the configuration will always be adapted according to the specific needs of your pallet racking and warehouse solution.

Chipboard support

Pallet racking beams are configured in pairs to support the stored load equally on both beams. When storing small sized goods which are not stored on pallets or inside containers it is not possible to place the goods on both beams.

When this is the case it is possible to opt for an extra connection between the beam pairs in the form of chipboard support profiles. For the storage of loose small goods the profiles will have a lowered top. This lowered top creates a space for the placement of a chipboard shelf. The shelf will be levelled with the beams of the racking, thus creating a flat full surface to store the loose goods. The profiles can be fixed to the beams using self-tapping screws. The number of profiles and the configuration will always be adapted according to the specific needs of your pallet racking and warehouse solution.

Pallet stop

When placing pallets in a pallet rack the user always strives to place the pallet on both beams of the beam pair. It is possible to equip the beam levels with push-through protection (or “pallet stops”) to make the placement smoother and safer.

This protection is placed at the back of the frames at the height of the pallet. When the driver is placing the pallet and he tries to push it too deep in the racking the pallet will be slowed down by the protection stop. This prevents faulty placement of the pallet, but also ensures that the driver does not accidentally push a pallet, on the pallet rack standing back-to-back, from its location.

Push-through protection is available in different versions, each with their own area of application. The type of security will always be determined based on the specific needs of your pallet racking and warehouse solution.

Mesh and grid shelving

When storing loose small goods metal mesh boards or grids provide an alternative to the chipboard shelves with lowered support profiled. This solution serves the same purpose as the chipboard shelf, but is manufactured from metal and does not create not a full surface.

Goods stacked loosely on pallets can become unstable when placed in the racks for a prolonged period. This can occur due to movements in the warehouse, vibrations in the rack structure, piece picking from the goods, etc. Mesh boards provide a barrier that prevents the goods from falling to the ground and injuring someone.

This solution is mainly used in tunnels where machines and personnel move underneath the stored goods. Another frequent use of the mesh is with warehouse solutions where personnel carries out ‘picking’ assignments on the bottom levels of the pallet racks. Equipping the first beam level with mesh shelves will guard the people working underneath the racks. Mesh or grid shelves can be applied in many other areas of the pallet racks depending on your warehouse solution.

Mesh fencing

In the same way that mesh panels prevent loose goods from falling between the beam pairs, a mesh fence prevents the goods from falling down the back of a row of pallet racks.

This solution is mainly used for a single rows of pallet racks (where there aren’t two rows of racks standing back-to-back). If the single row is not placed against a wall it will have an open back which you want to secure. However, this solution can be used for multiple purposes. For example, one can demarcate zones, create cages for the storage of dangerous goods, etc.

The mesh fence will be designed according to the requested solution and its requirements. The dimensions, design, grid spacing, etc. will be adapted to the needs of the warehouse solution. The fencing can also be equipped with doors, passageways and gates.