Considering a Hybrid Racking Concept for Busy, High Traffic Departments?

June 23rd, 2009

Pallet racking systems have traditionally been made from either structural steel or roll formed components.  Structural steel is thicker and far more abuse resistant, which is an important aspect in a very busy, high traffic department like dry grocery for example. Structural steel is typically more expensive than the roll formed racking components created from sheet metal bent into different sections to produce upright frames, beams and safety bars.

Key to any racking layout is preparing for properly sized aisles in the planning stages to minimize the risk of damage occurring during regular operation.  Regardless, the possibility for damage remains.  For example, lift truck damage to the storage racks typically occurs at the front post of the rack upright as careless or hurried operators swing into a slot to deposit or remove a pallet, accidentally connecting with the front or side of the upright post.

We attempt to minimize such damage by specifying angled deflector shoes be welded at the base of those posts, but “accidents” can still occur.  Another location where abuse frequently takes place is at the lower beam levels, and typically, directly behind the operator.  As he backs out of the slot with the pallet ahead as his main focus, damages occasionally occur to the lower beams across the aisle.

Some rack companies have recently suggested a “Hybrid” scenario that combines the strength and durability of structural steel and the economics of roll formed equipment as a cost efficient option.

With the lift truck as the main culprit causing damages, we suggest only the beam levels higher than 100″ above the floor be roll formed.  The very narrow aisle (VNA) environment, where the mobile equipment is either turret trucks or man up order pickers, is another prime candidate for roll formed components as these machines are guided down the center of the aisle and do not come in contact with the racking.

The one true constant in the business world is change, and a company’s rack layout today may not reflect its requirements for the future.  Flexibility and compatibility must rate as important criteria in the long term planning process of any project.  If you start out with a mix of components there is a greater potential you’ll have problems with compatibility and thereby limit your flexibility for future changes down the road.

Typically, the greater the mix the greater the number of components to be manufactured, shipped and installed.  Depending on the extent of the mix of between structural and roll formed, there could be double the number of components on site for any given project.  Overall, this logically implies that the resources required to keep track of all of these items may outweigh the initial cost savings expected for the project.

A prudent approach to the “hybrid” option is to keep the mixture confined to areas such as Conventional and VNA, as an example, to keep project costs to an acceptable level in relation to the potential benefits to be derived.

Entry Filed under: Material Handling