Frequently Asked Questions

Wire decks are a type of pallet support comprised of wire mesh formed over steel channels. They are available in different styles, with the most common being waterfall wire decks. Waterfall decks hang over the outside of pallet rack beams. They are the ideal choice for most warehouses as they prevent pallets from falling through the beams, and can also catch smaller loose items.

Bolted pallet rack and welded pallet rack have been the subject of debate for a while now among manufacturers and warehouse owners. Bolted pallet rack (uprights that are bolted) is more common in Europe, and welded rack (welded uprights) is more common in North America. Although most people feel strongly about one or the other, there are advantages to either type of pallet rack.

Roll formed pallet rack is more lightweight, less expensive, and is easy to adjust and install. Structural pallet rack is stronger and uses more steel, so it is more expensive than roll formed. It can take more abuse from forklifts, so it is ideal for a system where forklifts are driving in and out of the rack.

Both drive-in and push-back rack are based on a LIFO (last in first out) inventory system, however, push-back rack allows more selectivity since you don’t have to remove all of the levels to access the pallet behind it.

Learn more: Push Back Pallet Rack
Learn more: Drive-In Pallet Rack

It depends. If you are in the market for used pallet rack, you will probably have to be flexible on the type and size of rack you need. If you limit yourself to used rack on a tight timeline, you may end up with rack that is not the ideal fit for your facility and/or product. Often, new rack that meets your exact criteria is not much more expensive than going with used rack. It may even be less expensive!

The most common pallet rack beam lengths are 4’, 8’, 9’, 10’, and 12’. Based on common pallet sizes, other beam lengths are not typically required.

Standard pallet rack depths are 36”, 42”, and 48”. Upright heights are generally standard as long as they are in even foot increments. The most common upright heights are 8’, 10’, 12’, 16’ & 20’.

Roll-formed Teardrop is the most common style of selective pallet racking. Most manufacturers have a version of teardrop rack that they make, and the parts are usually interchangeable with other brands, although there are some exceptions.

Cantilever Pallet Racking is ideal for storing long, bulky items such as pipes, lumber, and textiles. Double and single-sided units are available, allowing you to store items on one side, or both. The arms are adjustable to accommodate your changing inventory. With no front column, this rack is easier to load and unload, as well as adding space due to less structure.

Carton Flow Pallet Rack is FIFO, and ideal for storing multiple product SKUs. It is gravity driven, allowing the materials to glide down the lane using different types of roller tracks. The difference between pallet flow and carton flow is that carton flow is used for light, hand-stacked items rather than full-sized pallets. The tilted shelves improve visibility and picking accuracy. Less floor space can be used while transporting the products through the lanes, as well as different levels, increasing storage capability.

Pallet Flow Racking functions as first in, first out (FIFO), making it a good system for time sensitive but a limited amount of products, such as a certain types of food. It is gravity driven, and pallets are loaded from one side and gravity rollers transport them down to the picking side of the rack.

Push Back Pallet Racking allows greater selectivity than drive-in pallet rack. It is also a LIFO system, but multiple products can be stored because each lane and level are accessed independently. In this case, different pallets could be put in next to each other, but it would be the same pallet in a row, leaving the first pallet in to be the last one accessed again.

Drive-In Pallet Racking works well with a limited number of products. It requires standardized pallets throughout the system, and is last in, first out (LIFO). This is because the drive in lane is one way, so the first products you put in would be the last you would be able to get back out. This system requires experienced forklift drivers since they actually drive the forklift into the lanes, which can be dangerous.

Selective Pallet Racking is the most commonly used warehouse storage system. This type of rack provides individual access to each pallet, allowing you to store multiple items with easier picking. The basic components of selective racks are the uprights and beams. Uprights are the column part of the rack, and beams go across to attach to the upright, forming the structure of the rack. Depending on the type and size of these components, you can store a lot of different pallet types in this system.

Wall ties are used if you have a single row of pallet rack against a wall. It connects the structure to the wall, providing stability. They are often required if the pallet rack is above a certain height.

Row spacers are meant to space pallet rack that is placed back to back. They connect upright to upright, and are used for a few different reasons. First, they keep the aisles in line and neat, making your warehouse look more organized. They provide spacing between the two bays of rack so that the pallets don’t damage each other. Lastly, they stabilize the pallet rack. A 12 inch spacer is the most common, which allows for a 3 inch overhang on both sides, and 6 inches in the middle between loads. However, other sizes are used if there are different circumstances, like if there is a column in the way and the rack needs to be further spaced apart to get around it.

Wire decks are designed for a capacity based on a uniformly distributed load (UDL). If you have point loading, such as a container with supports or a pallet smaller than your wire deck, you may see some deflection if the deck is not designed to support those concentrated load points. We recommend adding pallet supports (crossbars) or we can design a deck made for your load.

Most pallet supports and crossbars are designed to fit on the outside of both beams and attach to the front of the beam. These may be called flanged or waterfall pallet supports.

There are also pallet supports that rest inside of roll formed step beams. Some of these supports may have a lower offset to allow for plywood or solid decking to fit on top of the support and inside the steps of the beam allowing for a level surface. It is recommended that you tek screw these supports to the beam to prevent them from moving.

There are also roll-in pallet supports and crossbars that require a pre-punch inside of the step beam. These are easier to install and can be secured without hardware.

Wire decks are easy to install and require no hardware. On the other hand, it is recommended that you tek screw any pallet supports and crossbars to the beam. For this reason, the cost of wire decks versus pallet supports can be similar once you include the labor cost of attaching the supports.

At least two supports are recommended per pallet position. Most beam levels have two pallet positions, so four pallet supports would be required per level. Check the capacity of the pallet supports against your pallet to determine if additional supports are needed.

Steel shelf panels are ideal for loads that require a smooth surface with no perforation. They should only be used for rack storage under 12’ since they are not perforated for fire safety. They may be a better choice for environments that are subject to some moisture because in that case particle board would not be an option.

You should only use plywood or particle board in your pallet rack if you are storing items below 12’. These options are not acceptable for high pile storage since they are not perforated for fire safety. Plywood or particle board levels are typically supported by lumber underneath and are ideal for storing small items in your rack, especially if you need a smoother surface. They can also be used for double deep racks to create a solid surface from the front to the back of the double deep system. This is ideal for storing rolls of carpet or other long items.

Pallet rack cross bars are steel supports that can fit inside or over pallet rack beams. They prevent pallets from falling between the beams and also prevent beams from spreading over time. They are a good choice if you are storing only full pallet loads and do not have concern for smaller items falling through your racks. They are typically a more economical option than wire decks as well.

We stock several support and deck options for your pallet racks. Depending on the application and what you are storing, wire decks, cross bars, particle board, or steel shelf panels could be good options for your rack.

Some type of support is recommended for your beams. Not using any support could allow your pallet or product to fall causing possible injury or product damage.

Some pallets may not reach the depth of your rack and do not sit directly on the beam. Or the depth of the pallet is the same depth as your rack upright and requires the forklift operator to place the pallet precisely on the top of the beams, front and back. These are good reasons to consider supports.

You can, but it can be more challenging. One of the critical parts of the permit application is the PE Stamped structural drawings and seismic calculations. In order for the engineer to do the calculations and stamp the drawings with confidence, he or she must know the specifications of the racking involved. With new rack or easily identifiable used rack, this process is relatively easy because the information is available directly from the manufacturer. With used rack, this can be very difficult unless the rack is stamped with the manufacturer’s model numbers on each component. A significant portion of the used rack in the market does not have any identifying marks, and therefore it is nearly impossible to know the exact specifications.

This process for a pallet rack permit varies depending on where your facility is located. You usually start by making sure the building has the necessary equipment, including safety equipment. Then, you apply for a permit review date to get your site reviewed and approved. In the meantime, we usually gather the documents that are needed.

Applying for a pallet racking permit (high piled storage) can be long and complicated, and varies from municipality to municipality. You’ll need different documents, approval drawings, site visits, calculations, and approval by the local building and fire departments to be sure you are up to code.

If you are planning on having any pallet racking systems installed in your warehouse, you probably need a permit. Most city building codes require getting a permit when you are storing inventory of a certain height or higher, and/or you have combustible storage (this includes the packaging, the pallet, and the items). Depending on your location, however, this permitting process can vary greatly.

You should have trained professionals install your pallet rack.

We offer pallet rack repair kits for damaged uprights. Rack repair is a good option if the damage is low and affects only the front column. It is also ideal if you need the damaged upright replaced quickly while causing minimal disruption to your operations. Rack repair kits can be installed while your rack is still loaded. See our rack repair video by clicking the link below to better understand the process.

Pallet rack replacement is preferable if the damage to your racks is higher on the upright, especially if it is at or above your first beam level. Replacement will likely be less expensive if you uprights are short or the damaged upright is on the end of a row. Our sales reps can help you determine if rack replacement is the more economical option.

If the damage to your upright is clearly visible, we recommend that you look into repairing it or replacing it. Damaged uprights are no longer structurally sound and are a safety hazard. We can send a representative to your facility to perform a survey to determine how many uprights need to be repaired and/or replaced.

Learn more about pallet rack repair.

Forklift drivers are required to be certified according to OSHA, but many people don’t know that. Accidents can cause injury or death, and if your drivers haven’t passed the class, your business could be fined.

The class averages about three hours, but can go longer. The practical, hands-on portion varies in length depending on the candidate’s dexterity.

Certification does not need renewal unless the certified party is involved in an accident or wished to be licensed on a different type of lift.