Low cost upgrades can prolong storage rack system life
You can reduce rack system damage by selectively reinforcing damage prone points.
By David Luton -- Modern Materials Handling, 5/1/1999
Careful attention to detail can often provide significant added value in a materials handling system at only a modest cost increase. For example in racking it is possible to reduce rack system damage by selectively reinforcing damage prone points.Take the basic example of a system with 200-ft-long rows of selective roll formed pallet rack for 48 in. x 40 in. pallets. In our example we will assume a design with 25 frames with a tunnel in the midpoint to permit easy aisle changes.
In our system& - like all storage systems - the most important way to avoid rack damage is to have a properly designed materials handling system. Once this is done the next important step to take is to identify the points most prone to damage and reinforce them.
There are four exposed frames in our system - the frames adjacent to the tunnels and at the end of aisles are the most damage prone. These frames account for only 16% of the total system.
The accompanying sidebar points out some examples of selective rack reinforcement.
You will note that within the frames we emphasize that the bottom portion of the rack is that part most prone to damage.
The protection needed for interior racks is also a function of product turnover and handling equipment used.
If your handling equipment (for example, a counterbalanced lift truck or a reach truck) makes a right-angle turn to place product into or remove it from the racks, then the damage potential is increased. In many cases it's the exposed outriggers that cause the damage. Using angle deflectors welded to the bottom of the frame can reduce this type of damage.
Even reinforcement of exposed frames cannot prevent all types of damage, such as a fork spear. In this case, the prompt replacement (very carefully) of the damaged frame is desirable.
As illustrated by the preceding examples, there is more to supplier selection than a low price. Next time you have a rack project for suppliers to bid on, ask your vendors how they can increase the value by improved design rather than just cutting the price.
Reinforcing your rack system
There are a number of steps that you can take to beef up your rack system against damage. They include:
* Impact or frame protectors at the end of aisle that are lagged to the floor rather then attached to the racks so that they can be removed if damaged.
* Additional or larger lag bolts in these positions are also desirable.
* A double front post especially at the bottom. (Alternatively, try using a channel insert)
* A heavy-duty bottom horizontal (bottom brace) and a heavy-duty bottom diagonal.
* A heavy-duty bottom row spacer.
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