Which Type of Pallet Racking is Best for My Warehouse?
There are a number of different types of pallet racking systems available today. Even seasoned warehouse operators may be challenged to fully-understand the features and benefits, positives, and negatives of each type of racking. In this blog post, we hope to provide helpful information on the different types of pallet racking, suitable applications, general costs per pallet position, and other variables for your consideration.
Let’s start by reviewing the three main methods for manufacturing racking.
Roll-Form Rack
The most commonly manufactured rack is made from cold-rolled steel. It’s lightweight and offers exceptional strength and durability. Components are typically “boltless” and with a “teardrop” design for easy installation and adjustment of beams.
Structural Rack
Beams and uprights are created from hot-rolled steel channels. A structural rack is generally more costly than roll-form rack, and due to the need to bolt together the components, takes more time to set up or reconfigure.
Tubular Structural Rack
While the load capacity of conventional pallet rack frames can exceed 30,000 pounds, tubular structural rack is capable of handling more than 70,000 pounds. It is also impact resistant and may be implemented for seismic locations, rack-supported buildings, and tall AS/RS. It may also be implemented for special sanitary operations, when specifications call for rack made without any holes.
Now, let’s turn our attention to eight major types of racking, their general applications, cost ranges per pallet position, and other important variables you will want to review.
Selective Pallet Racking
Selective pallet racking is the most common type of racking. Its single deep storage offers easy access to all pallets.
Large applications have an estimated per pallet position: $100.00 to $125.00
Variables: Rack height, load weight, and aisle width
Double-Deep Pallet Racking
Double-Deep pallet racking is a variation of Selective pallet racking. As the name implies it provides two-deep pallet positions. This rack is popular for freezer and cold storage operations, or any application desiring the ability to store pallets two deep.
Large applications have an estimated cost per pallet position: $100.00 to $125.00
Variables: limited selectivity, FILO (First-In, Last-Out)
Drive-in / Drive-Through Pallet Racking
This is a high-density storage system, designed so that forklifts actually drive directly into or through the pallet racking. Drive-through offers additional access at the open ends of the rack structure. This type of racking is often found in applications with large numbers of the same products, such as beverage manufacturers, and food distributors with coolers and blast freezers.
Large Applications have an estimated cost per pallet position: $250.00-$300.00
Variables: Reduced load/unload efficiency / Honeycombing / FILO (First-in / Last-Out)
Push-Back Racking
Push-back racking systems utilize carts to store pallets up to four or five deep, on a slight incline, which provides 2x to 3x the amount of storage space as compared to traditional selective pallet racking. The two general types of push-back racking are push-back with carts (also called shuttles) and push-back with rollers.
Large Applications have an estimated cost per pallet position: $350.00 – $400.00
Variables: Depth of rack system and quality of the carts or rollers, LIFO (Last In / First Out) not FIFO
Pallet Flow Racking (Gravity Flow)
Pallet Flow racking uses rollers (aka skate wheels and takes advantage of gravity to provide a good high-density storage system. Pallet Flow works with the FIFO (First-in / First-Out) system.
Cost per pallet position: $350.00 – $400.00
Variables: Complexity and Maintenance needs of the roller system, load capacity and system depth
Cantilever Racking
Cantilever racking is ideal for storing long items such as lumber or pipes. It’s relatively easy to set up and reconfigure and is available in a broad range of capacities.
Cost per pallet position: $150 to $200
Variables: Arm length and capacity, rack height and overall configuration
Mezzanine Racking
Mezzanine racking utilizes vertical space to create additional floor levels for storage.
Large Projects have an estimated cost per square Foot: $50.00 to $75.00
Variables: Structural complexity, Load capacity per level, compliance with building codes
Automated Storage and Retrieval Systems (AS/RS)
These systems use automated vehicles in an enclosed system to provide storage and retrieval.
Variables: Level of automation, Integration with warehouse management systems (WMS), Customization and scalability
The costs per square foot listed here are general estimates and will vary from project to project. Costs are dependent on factors such as the overall size, layout and design of the warehouse, the amount of customization required, the skill and efficiency of the installation crew, local compliance regulations, and regional factors such as labor costs and seismic requirements.
It is always important to work with a reputable material handling and storage solutions company or systems integrator to receive detailed, professional analysis, accurate estimates for your specific storage needs, and safe, efficient installation. Eastern Lift Truck Co. offers all of these products and services and checks all of these boxes. We sell and install a high volume of racking, and even stock it for quick-ship purposes. Contact us today to start a conversation about your next warehouse project.
