Pallet racks are a great way to manage your storage management and maximize space capacity to improve efficiency and inventory accessibility. Warehouses and distribution centers use pallet systems to reduce inventory management costs and boost productivity.
However, the success of a pallet racking system highly depends on its proper installation. A well-installed racking keeps your inventory safe and ensures worker safety. Besides, you can reduce retrieval time to streamline workflow. It also maintains structural integrity, preventing collapse.
How to install pallet racking step-by-step
Train your crew
Pallet racking installation starts by training your crews to ensure proper safety and complaints. Gather your crew to provide enough information and demonstrate the process. It involves wearing protective gear, properly lifting heavy components, and securing every component.
Determine your storage needs.
Knowing storage needs is essential to select the right rack and design the layout. List down the inventory you want to store. Note their sizes, shapes, and weights. Consider handling requirements and accessibility. These will help to determine the storage needs.
Assess the floor space and make the site ready.
Measure floor area and ceiling height to check whether it fulfills the storage requirement. Consult an engineer to know the weight capacity to understand whether it can support the fully loaded rack weight. Clean the area and remove dust and debris. Remove obstructions such as pillars, overhead beams, piping or electrical panels, and light fixtures.
Create a layout drawing to show pallet row and aisle spacing
Use software or grid paper to design the layout. It shows the front view of the pallet rows with beam level elevation. Leave enough room in the aisles for forklifts and maintain easy access to emergency exits and pathways. Hire a professional for the design to avoid any errors.
Mark the floor
Measure the area and mark the positions following the drawing. Use chalk to mark each spot on the open floor space where each upright frame will stand. It helps you know where to install the racks. Double-check the marking to avoid misalignment and stability issues.
Unload the rack
The racks usually come in flatbed trailers. Unload them safely and securely to avoid injuries and damage. Ensure all parts, such as upright frames, horizontal beams, connectors, anchors, wire decks, and others, are present. Lay out the parts by type for smooth installation.
Assemble and stand upright.
Lay two posts on the ground and connect the post foot using bolts and nuts. Secure the cross bracing as per the manufacturer’s instructions. Attach horizontal and diagonal brace. Ensure it’s vertically level using a level. Use clamps or support to keep the frames steady.
Erect the bay
Erect the first bay and place the upright in the exact marked position. Follow the same method for the second bay. The alignment has to be level, and no more than 1/8 inch tilt is acceptable.
Rack anchor and Install the connectors.
Use a concrete drill to create holes at the upright base. Follow the manufacturer’s guidelines for hole depth and size. Use connectors such as wedge locks, t-blocks, or bolts to secure the uprights. They keep the beams in place. Ensure the racks are a perfect fit for the overall safety and stability.
Install the beams (front and rear beams)
Lift the rear bottom beams and slide their ends into the slots on the upright. Both ends have to be locked into the correct position. Use a rubber mallet to ensure a snug fit. Level the beams for a stable structure. Insert locking pins or clips to prevent dislodging. Follow the same method for front beams. Finally, attach the bottom beams.
Finish Remaining Bays
Measure the square of the first bay to avoid installation errors. Then, erect the remaining bays following the same method.
Install wire decks
Pick the best shelf or wire deck to handle the inventory load. Wire mesh decks are good for food, retail, and manufacturing goods due to their strength, versatility, and ease of use. Lay the decks onto the beams. Center the decks and cover full width. Use clips or fasteners to secure the decks for added safety.
Install column protector
Some racking systems require a column protector for added stability and constructional integrity. Pick a suitable protector, such as snap-on, bolt-on, or wrap-around, and tighten them properly.
Should you hire a professional for pallet rack installation?
Yes, you must hire a pallet rack installation professional to avoid errors. You can only install pallet racking with help from a professional if you are a pro. Installing such a vast rack requires expertise, time, and manpower. Besides, it would be best if you had specialized tools and equipment to install the racks. Training crews to avoid injuries and maintain safety and state regulations is also essential. If you lack any of those, you must hire a professional.
Best pallet rack installation company
Matco distributor is one of the best rack installation companies with more than 75 years of experience in this industry for offering different types of pallet racks, including selective pallet racks, drive-in pallet racks, pushback, pallet flow, and wire decking. Their quality and affordable pricing allow customers to install racking without spending too much. Besides, they always maintain compliance and safety guidelines.
Safety precautions while installing a pallet rack system
- Always wear helmets, gloves, safety glasses, steel-toed boots, and reflective vests.
- Before installing, inspect the floor for cracks, uneven surfaces, or other damage.
- Use the right equipment and tools.
- Follow manufacturer guidelines.
- Secure upright frames to avoid accidents.
- Anchor the system and install beams properly.
- Know the loading capacity and avoid overloading.
- Comply with all federal, state, and local regulations
Pallet rack installation cost
The average cost for a single pallet position is $55-$200, $85- $300 per double-deep pallet position, and $200 to $400 per gravity-flow racks pallet position. However, the cost will vary depending on the labor cost, material type, location, and size.
Wrapping up
install pallet racking is not tough when you have experience, expertise, tools, and manpower. These are not available for any distribution or storage company. It is better to leave the task to the professionals to avoid errors and ensure safety and security.
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