Pallet Racking Installation Guide | How to Secure Pallet Racking to the Floor

Countless manufacturers and distributors require vast amounts of storage. With traditional storage methods, accessing products can be tricky. But with pallet racking systems can help solve storage space restrictions and are a versatile alternative to other options.

However, pallet racking installation isn’t simple. It takes planning, time, skill, and experience to do it properly and safely. There’s no question– installing pallet racks is a challenge. In almost all cases you should hire a professional to complete the installation, including securing it to the floor. If you’d like to learn more about how to secure pallet racking to the floor, continue reading our detailed guide.

What is Pallet Racking?

Before we get into how to secure pallet racking, let’s review what it is first. Pallet racking is a storage system that utilizes otherwise unused vertical space. Unlike traditional storage options that primarily store everything at ground level, pallet racking builds on top of itself. Pallets sit in numerous tiers situated in horizontal rows.

These systems promote the organization of materials, helping to increase efficiency and cut back on stock picking time. Although there are many different designs and layouts, pallet racking makes materials easily accessible using a forklift truck.

What Are the Major Uses of Pallet Racking?

Many companies, especially general warehouses and OEMs, use pallet racking systems. These systems are primarily used for storage and are outstanding solutions, as they provide a multitude of benefits that other storage systems can’t provide.

For example, they are exceedingly versatile and can meet varying specifications in different scenarios. Products stored on pallet racking systems are easily accessible, adding to the convenience and efficiency of the workers. Additionally, pallet racking systems are easy to assemble, and replacing parts is quick and straightforward.

Companies with a “first-in-first-out” process usually use gravity flow racks, given their ability to efficiently cycle products, thus ensuring older products are used first. Large warehouses can make great use of their vertical space, building racks up instead of expanding the building. Stored materials and products are easily accessible using a forklift truck.

Different Types of Pallet Racking for Warehouse Storage

There are many types of pallet racking. Warehouses of varying shapes and sizes can implement pallet racking. Each variation is slightly different, further promoting the versatility of these systems. It goes without saying that they are highly customizable.

Here are some examples of pallet racking types:

• - Selective pallet racking – The most sought-after pallet racking system in the industry. These systems are known for ease of immediate accessibility, given the single-deep nature of the design.

• - Double-deep racks – As the name implies, they have two rows of selective racking, one behind the other. This option is an inexpensive way to increase storage capacity.

• - Push-back or back racking systems– These rely on carts that move forward as the pallet in front is removed. The concept reduces picking times and allows for quick access to products.

• - Pallet flow (gravity flow) racks– use a sloped system that circulates products efficiently. New products are added to the high end and removed at the lower end, helping ensure that the oldest product always goes out first.

• - Drive-in or drive-through rack systems– are the most high-density storage systems available. They can store up to 75 percent more pallets than the traditional pallet rack system and are accessible via a forklift truck that can drive directly into the rack.

Top Considerations Before Installing Pallet Racking to the Floor

If you’re installing pallet racking in your facility, you need to consider numerous factors before installation. Although pallet racking systems are an excellent solution for maximizing storage space, they must be installed correctly.

Failure to properly install these systems can reduce efficiency and cause safety concerns for both the products and your employees.

Complete knowledge and understanding of the space in question are also necessary, which include the following factors.

Floor-type

The type of floor in the space is an essential factor in determining safe protocol. Certain materials will be easier to adhere a rack to than others. Pallet racking is generally secured to concrete floors using a concrete wedge or strike anchor.

However, specific lightweight systems can be installed on differing materials, such as wood decking. It is best to have an experienced engineer on-site to advise how to affix the racks in these scenarios.

Sloped floors can complicate pallet rack designs, and RMI specifications presume that flooring is flat. Specifications are designed around the assumption that it doesn’t exceed 0.5-inch in 10 feet of height that differs from the true parallel with gravity. If the warehouse floor is sloped, then adjustments will be necessary.

Space Dimensions

Before installing pallet racking, the individual must thoroughly evaluate the area. Since vertical space plays a critical role in pallet racking systems, it must be considered alongside floor space. Consider the amount of room necessary to safely maneuver a forklift into the space to access the product.

Inspections

Professional engineers should inspect the anchoring system before installation. Enlisting the help of a professional will ensure important details aren’t missed. An engineer can also disclose further information surrounding the design, including how many anchors your system needs, the type of anchor bolts required, and the number of holes to use in the base plate. In general, they’ll ensure it is safe and stable.

Seismic activity in the area

Some areas that experience seismic forces will need to account for such activity in their build. The American Society of Civil Engineers (ASCE) outlines regions with a seismic design category (SDC). If the facility is located in certain regions, you may have to meet additional seismic requirements.

Impact Protection

Even though they are designed to resist force, base plates and anchors are susceptible to impact from heavy-duty machinery, like forklifts and pickers. You must thoughtfully plan layout designs to leave enough space for forklifts to move around the racks.

However, in addition to a meticulously laid out plan, there are several ways that you can protect mount anchors and reduce the effect of any potential impact. Increasing the quantity and size of anchor bolts on aisle-facing columns will help with any impact to the aisle, as will welding steel plate column protectors to the base plates.

Additionally, installing guards on column posts, whether plastic, steel, or foam, offers additional protection.

Every component needs to be correctly labeled with a weight rating and fastidiously inspected for safety purposes, preferably by a professional.

How To Prepare for Pallet Racking

Properly securing pallet racking systems is imperative for the safety of employees and the products on your shelves. Warehouses need to follow strict safety guidelines to secure pallet racking to the floor. Requirements vary based on the type of system.

For example, facilities with a restricted area to work with may choose to implement a narrow aisle system that will allow for room to maneuver the forklift. On the other hand, warehouses with wide, open spaces have numerous systems to choose from. Safety guidelines for these systems are slightly different from their narrow counterparts.

Developing a plan is a critical step in avoiding unwanted consequences of unsecured pallet racking systems. As you concoct your initial plan, remember to consider aspects such as:

• - Local building codes
• - Type of storage racks, including whether you are using new or used pallet racks
• - Dimensions of the space - account for any overhead ducts, lighting, and the like
• - Additional safety measures, such as aisle protection
• - Necessary space to maneuver forklift in and around the pallet racks

In addition to each of the aspects mentioned above, consider implementing a training plan for your employees. Failure to use correct safety precautions while using a pallet rack could potentially lead to traumatic injuries and product loss. Therefore, training all employees how to properly store and handle items on the racks and unsafe actions to avoid is imperative for safety.

A labeling system helps streamline the process of storing and retrieving products.

Install Pallet Racking Correctly To Provide A Safe Working Environment

Proper installation and inspection of pallet racks are mandatory for the safety of employees and products. The Occupational Safety and Health Administration (OSHA) doesn’t have a specified stipulation targeting pallet rack security.

However, in the OSHA General Duty Clause Section 5(a)(1), it is explicitly stated that employers must provide a safe workplace for employees. Since improper installation can lead to safety hazards for employees, OSHA’s statement generally encompasses pallet racks.

How To Secure Pallet Racking To The Floor

To avoid harsh penalties, regular inspection, maintenance, and proper installation are crucial. While installing pallet racking systems, carefully follow the manufacturer’s instructions. Wear safety goggles, and be sure to handle each of the tools with utmost caution. To install the Dyna bolts, follow these steps:

• - Drill the necessary holes using a hammer drill and masonry bit with the holes in the base plate as a template. Ensure that the drill bit is the same diameter as the Dyna bolt.
• - Carefully insert the Dyna bolt into the hole, place the washer on and thread the nut a few turns. By not entirely threading the nut, you will protect the threads of the wedge anchor.
• - Next, insert the bolt into each hole through the baseplate of the upright racks. Hammer the anchors into each hole. Ensure you install them to the desired depth.
• - Finally, tighten each of the nuts with a torque wrench. Verify that they are tightened enough to meet the torque value requirements.

Once you finish tightening each of the nuts, check all other fittings and anchors. This includes all fittings or anchors on beams, floor racks, and decking. A final run-through before you begin storing items on the racks will help catch any details you missed.

Note: If you’re inexperienced with pallet racking, our team at The Safety Source can help. Give us a call today.

How Often Should Inspections Happen?

Routine inspections are imperative for employee safety and product security. The owner or manager of warehouse operation is in charge of enforcing a routinely scheduled inspection plan. According to OSHA, a qualified person needs to conduct the inspections.

The inspector must be certified and have extensive knowledge, training, experience, and successful history of being capable of doing so. Professional pallet rack installation providers and representatives from the racking manufacturer are examples of such.

A manager or team of employees should take on self-guided inspections. Whoever is given the assignment needs to be trained on which areas to inspect and proper protocol to follow should replacements or repairs be necessary.

Although inspection schedules are dependent on the specific situation, inspections should generally be completed at routine intervals, such as:

• -Weekly: Each week, the safety management team or officer should inspect the pallet rack storage area during a thorough walkthrough. Once the visual inspection is complete, the officer or team should document and report any concerns.

• -Annually: Whoever is in charge of scheduling inspections should ensure that the storage system is professionally inspected at least once a year. Since professionals have training, experience, and knowledge regarding rack system safety that many warehouse teams may not, they are more likely to catch any safety concerns.

Professionals will usually ask several questions regarding the rack system, such as dimensions, type, manufacturer name, and the like.

• -Post-damage: After any incidents, such as repairs, damage, or safety situations, schedule a professional inspection immediately. Even minor damage, such as small dents, can upset the load balance of the system.

• -Following changes: If the warehouse rearranges, downsizes or expands, or restructures, it is best to schedule a follow-up inspection. Anytime the rack system is resituated, inspectors must thoroughly recheck vital areas for safety and optimal function.

Areas that need regular inspection include:

• -Bowing areas: Visually check all racks, crossbars, and beams for signs of bowing, bending, or breaking. Closely monitor areas that are bending. Although some deflection is typical, watch for signs of overloaded racks, as they can quickly become a safety concern.

• -Corrosion and rust: Track any spots of rust, corrosion, or discoloration. These can cause substantial damage, especially constant water exposure and friction from two racks or pallets rubbing together.

• -Bracing and anchors: Verify the structural integrity of anchors, bracing, and baseplates. Tighten as necessary.

• -Screws and bolts: Check for any screws that are loosening. Replace damaged or removed screws as necessary.

• -Netting and protectors: Check netting and protectors for signs of breakage or corrosion. Verify that welding is securely intact.

• -Connectors and locks: Verify that safety locks and beam connectors are secure and free of visible damage.

• -Labels: To help with organization and safety, ensure that all labels are easy to read and not worn. Labels should have load rating information, product information, and product weight.

• -Modifications: Temporary modifications or other quick fixes that are unsafe, such as steel beams supporting the racks, must be addressed and corrected immediately.

Conclusion

Pallet racking is an excellent storage option for numerous situations. They make use of otherwise unused vertical space while still facilitating accessibility to inventory. However, if they are improperly installed, workplace safety may become a problem, thus leading to several additional issues. Ensure that all proper steps are followed to verify that the pallet racks are as safe as possible.