FAQs

When is cantilever racking the ideal solution for your industrial warehouse storage needs?

Lengthy materials aren’t best suited to storage on traditional pallet racking. Because pallet storage bays are effectively boxes, with uprights at each corner, manoeuvring lengthy materials in and out of such spaces can be impractical and time consuming.

Cantilever racking uses a different form of construction to deliver its storage capacity. Multiple columns support cantilever arms. As length and load increase, you can simply add additional columns at equal distances along the load to increase capacity. Crucially, there’s no end section, which makes loading and unloading lengthy materials quick and easy.

Cantilever racking can be single or double-sided, with arms on just one or both sides of the upright, and can typically support significant loads.

What sort of materials can I store on cantilever racking?

If it’s lengthy, chances are it will be well suited to cantilever racking. Timber, trunking, piping, tubing and sheet materials may all be suitable for cantilever racking, and a standard front or side-loading forklift will usually be all you need to pick and load.

Be aware that materials stored in this way are liable to distortion if you use the incorrect number of racking columns (imagine, for example, how a long sheet of timber would sag if you only supported it at either end). It’s important, therefore, to ensure that loads are evenly distributed across an appropriate number of columns to protect the stored materials.

The right support and load spacing can also protect the integrity of your cantilever racking system, ensuring you can maximise its load capacity.

How high can my cantilever racking go?

The question of height depends on a number of factors including the load, the size of the racking base and the integrity of the warehouse flooring or walls (if the racking is going to be anchored to them).

For help in calculating your cantilever racking system requirements, maximum loads and heights, call Rack-Master now on 01422 300 644 or contact us

A chilled or frozen environment won’t dramatically affect your choice of pallet racking system. But the goods that you are chilling or freezing might do…

In terms of construction, conventional warehouse racking should be able to comfortably withstand the -18°C to -22°C required for frozen goods. If you need industrial racking that can cope with lower temperatures, you may need to consider an alternative approach.

Talk to us about this now.

Some chilled or frozen products may require hygienic, easy to clean surfaces and it is possible to install storage shelving that is coated with an antimicrobial treatment suitable for cold rooms, food preparation areas and hospitals.

Chilled rather than frozen storage areas will increase the potential for rust, so you’ll potentially need a galvanised racking system to limit the risk of corrosion.

How do I make picking and loading more efficient?

Rather than the racking itself, often the bigger issue is the swift access and frequent stock rotation that chilled or frozen goods typically require. To ensure stored goods are used in strict rotation, your picking system may need to adopt some form of first in, first out (FIFO) or 100% availability system, to ensure no pallets are left to linger at the rear of racks.

You can achieve this in a number of ways:

Mobile pallet racking

High density storage with fast availability of any pallet in any aisle thanks to the use of automated mobile bases, which can retrieve pallets as fast as any forklift driver. Ideal for storage areas with large numbers of SKUs.

Radio shuttle racking

A semi-automated and high-density storage solution in which remote-controlled shuttles automatically retrieve and despatch pallets. This system makes highly efficient use of space and cuts forklift load and pick times. It’s of particular value in warehouses with large numbers of pallet positions but relatively few SKUs.

Pallet live storage

Enables your warehouse to achieve high density storage without block stacking pallets, whilst maintaining a good flow of products. Pallets are loaded onto roller lanes at the loading face and roll to the off-loading face for a simple FIFO system that ensures good stock rotation.

Talk to Rack-Master

To find the right pallet racking system or warehouse storage for your chilled or frozen products, talk to us now on 01422 300 644 or contact us

If you’re planning to install a mezzanine floor in your warehouse, what legislation do you need to comply with?

Mezzanine flooring has lots of potential applications and we explore a number of them here . If you want to install a mezzanine, what practical issues do you need to consider first?

Do I need planning permission?

Unlike building extensions, mezzanine floors do not require planning permission. There are, however, other approvals you will need to get, and regulations you will have to meet.

Do I need to tell my landlord?

The definitive answer should be in your warehouse lease agreement, but almost certainly there will be a requirement to inform your landlord of what you’re planning. There may be a requirement to get their explicit consent before you start work – although, as mezzanines do not affect the fabric of the building, you may be able to avoid this, or make the approval process simpler and quicker.

Will my mezzanine floor require Building Regulations approval?

Yes, mezzanine floors should still conform to Building Regulations and should meet current health and safety regulations. Develop your floor with Rack-Master and we’ll ensure complete compliance with all regulatory aspects of your mezzanine.

Will my mezzanine need to meet fire regulations?

The question of whether your mezzanine flooring requires fire rating depends on its size:

• Where the floor is 10m x 10m in size or less, occupies less than 50% of the area of the building in which it is located, and is not permanently occupied, it does not need a fire rating
• Where the mezzanine floor is 20m x 20m in size or less, occupies less than 50% of the area of the building in which it is located, and is not permanently occupied, it does not need fire rating but will need an appropriate alarm system
• Mezzanines larger than 10m x10m without an appropriate fire detection and alarm system – and all mezzanines larger than 20m x 20m or which occupy 50% or more of the area within which they are located – will need to meet fire regulations

There are, however, numerous additional factors which can affect the above guide, so please seek advice before planning your mezzanine. Talk to us about your plans now.

Do I need to install a protected escape route?

This depends on the location and number of existing fire exits but, as a general rule of thumb, if your mezzanine floor is going to include offices or production areas (i.e. areas which are frequently occupied) you’ll need to install fire rated partitioning and fire doors around at least one staircase to create a protected escape route. We can do this for you.

For questions about mezzanine flooring, or to explore options for increasing your facility’s operational space, call Rack-Master now on 01422 300 644 or contact us

A round-up of all your cantilever racking-based FAQs.

What load will my cantilever racking take?

We’ve put together a specific section about cantilever racking loads.

Is cantilever racking suitable for outdoor use?

Yes. Naturally, that only makes sense if the materials you’ll be storing are also suitable for outdoor storage, but in the case of plastic trunking, UPVC soffits, metal piping etc, there shouldn’t be a problem. If you’re storing timber, ask us to add a canopy to the racking to help shield it from the worst of the elements.

Is my floor suitable for cantilever racking?

Your racking will need be sited on a concrete floor or concrete pads. Nothing else is suitable. It’s essential that your floor is assessed as part of the design process to ensure it is fit for the loads you’ll be storing on it.

Will my racking be more rigid if tied to the warehouse walls?

We never tie a racking structure into the walls of a building. That’s because, unless you know the tolerances, using the walls as the basis for a racking system may introduce unknown elements into the equation and increase the risk of system (and building) failure. The cantilever racking systems we install are anchored to the system’s own columns which will then be anchored to the floor.

The only time we will ever connect the racking to the walls is as part of a rack clad building, where the racking is built first and we then attach the building to the racks – but here, the walls have no load bearing role.

How long can my cantilever racking arms be?

This depends on:

• What you’re storing on them
• Load weights
• The picking and loading equipment you’re using

The first consideration for cantilever racking arm length is will your picking equipment be able to reach products at the back of the racks? Also worth considering is the potential for products to roll off the arms, and the increased load on each arm when you increase its length.

Talk to us about your cantilever racking system design and we’ll help you answer all the above questions, and create a warehouse racking system that helps you work more efficiently and cost effectively.

For help in calculating your cantilever racking system requirements, call 01422 300 644 or contact us

It’s a question we’re asked frequently. Here are the factors that influence the load capacity of your cantilever racking.

Load distribution

Whatever your cantilever racking’s load capacity, it could be reduced by 50% of more if loads are distributed unevenly. Cantilever racking is designed for lengthy, evenly distributed loads. If even distribution is going to be a problem, it may be that another racking system would better suit your needs. Talk to us about this.

Column capacity

Load doesn’t just pass through the cantilever arms; there are stress forces running through the upright sections of your cantilever racking too and it’s vital to remain within tolerances. Maximums vary depending on the column construction. Heavy duty assemblies will, naturally, carry more than standard columns and we will always discuss loads with you.

Arm capacity

We tailor the capacity of the arm to suit the product – the minimum weight would normally be 100kg and the maximum 1500kg. The higher the capacity, the thicker the arm. To take heavier loads, add additional arms on additional columns. This then enables you to divide the total weight across the total number of supporting arms and columns.

Floor capacity

Something that’s often overlooked is that any cantilever racking system will stand on the floor, and the floor needs to be able to bear the load too.

Column distribution

How many columns will your cantilever storage system require? Load isn’t the only determining factor – distortion is an issue too. If, for example, using two columns leaves the stored product sagging in the middle, then you’ll need to factor in an additional one or more columns until the distortion is resolved and the products are properly supported.

The space between columns should be equal. To calculate this divide the length of the load by the total number of columns to find the distance between the centre point of each column.

For help in calculating your cantilever racking system requirements, call Rack-Master now on 01422 300 644 or contact us

In this article, we explore how you should treat pallet racking safety inspections within your business.

Are warehouse racking system inspections a legal requirement?

Here’s what the HSE* says:

“To ensure that a racking installation continues to be serviceable and safe, the storage equipment should be inspected on a regular basis.”

By its own admission, the information published by the HSE is guidance, so following its advice is not a legal necessity. However, if your pallet racking is involved in a collapse or other accident resulting from its condition, the extent to which you followed the available guidance will be a factor in determining who, if anyone, is at fault.

So pallet racking inspections aren’t a legal requirement, but to protect your business and its reputation, you should probably treat them as if they were.

What other guidance affects pallet racking systems?

The HSE isn’t the only guidance concerning the condition of pallet racking. The Provision and Use of Work Equipment Regulations 1998 (PUWER) contain guidance on inspections of racking systems following installation or damage. And EN 15635 is the European standard the effectively ensures all of Europe adopts the same standard as that advised by the HSE.

* Warehousing and storage – A guide to health and safety (opens / downloads PDF)

Then, every 12 months (as a minimum), a “technically competent person” should carry out an inspection and submit a written report to the responsible person within the business. Their report should include observations and proposals for any action necessary.

As a SEMA-approved pallet racking inspector, Rack-Master has the technical expertise to carry out this annual inspection.

Talk to Rack-Master

To arrange your pallet racking damage survey, talk to Rack-Master now on 01422 300 644 or contact us

Why should I add a mezzanine floor?

Your warehouse space could be far more versatile than you realise. With mezzanine flooring, you could create storage, floorspace, workspace or office space without needing to extend your existing facility or buy/rent new premises.

No business buys or rents warehouse space that will futureproof it forever. Typically, you take on premises with enough additional capacity to allow for some growth, but once that growth outstrips capacity it’s time to look elsewhere. Before you do, consider this alternative…

Mezzanine flooring enables you to increase floorspace within the existing building without increasing the footprint of the space you occupy. It’s a ‘floating’, adaptable structure, capable of endless customisation as your needs evolve. And because you can use the space below the mezzanine floor too, you effectively free up double the floorspace occupied by the mezzanine.

How could I use mezzanine flooring in my business?

There are lots of ways to put a mezzanine floor to work in your business, and you can adapt the role of the mezzanine to suit your changing needs. Applications include:

• Additional storage – Many businesses need more than one type of storage. Mezzanine flooring enables you to introduce more (or different types of) storage to your existing facility or split the above/below mezzanine areas between storage and something else.
• Despatch – If you need an area for packing, checking, labelling and despatch, a mezzanine can provide all the space you need without compromising overall storage space.
• Workspace – From assembly areas to repair bays, if you’re currently renting additional space to house production units, consider the potential of a mezzanine floor to cut your overheads.
• Office space, training suites and breakout/social areas – When you’re already using every last inch of floorspace, often the only viable way to gain more room is to extend or buy/rent additional premises. With a mezzanine floor, you can give your business the additional m2 it needs for a fraction of the long-term overheads of acquiring additional space.
• Practical space – Trunk rooms, server areas and more can eat up valuable warehouse room. With a mezzanine, you can give the electrical cabling or telecoms the space they need far more cost effectively.

To find out whether mezzanine flooring would work for your business, read Mezzanine Flooring – What Do I Need to Consider?

For questions about mezzanine flooring, or to explore options for increasing your facility’s operational space, call Rack-Master now on 01422 300 644 or contact us

Mezzanine flooring has the potential to increase the usable floorspace of your industrial warehouse without extending or buying/renting additional premises. But is it a practical option for your business?

What is a mezzanine floor and could it fit into my warehouse?

Mezzanine floors are a steel-built ‘floating’ floor that can be virtually any size, restricted only by the size of the warehouse and fire regulations.

While there is no minimum height restriction for a mezzanine floor, your facility will need to offer a practical amount of space above and below the mezzanine to make its installation worthwhile. In addition, Building Regulations require 2m minimum headroom for any staircase.

Can you have multi-level mezzanine floors?

Yes, providing you have the space to fit more than one mezzanine floor (with required headroom) into your warehouse.

Will installing a mezzanine floor change my business rates?

Installing a mezzanine floor to be used for storage and general warehousing purposes should not affect your rates. If you’re using the mezzanine (or part of it) for offices, training suites or production areas, it may. Ask us about this.

How much disruption will be caused during installation?

We will need to cordon off the area identified for the mezzanine, but no other area of your warehouse should be affected. We work fast, so you’ll be able to have productive use of your mezzanine floor (and the area below it) quickly.

Is mezzanine flooring a cheaper option than extending the building?

Almost always. It’s cheaper (and far less complex and time consuming) than extending the existing building. It’s also likely to be cheaper than renting additional space or renting alternative space and moving warehouses.

Can a mezzanine increase the value of your warehouse?

Yes. And if you lease rather than own your warehouse, there may still be value in installing mezzanine flooring, providing the terms of your lease allow it. By increasing the useable space and the overall efficiency of the warehouse, you could increase the lease value of the unit, giving you valuable leverage when it comes to renegotiating with your landlord.

How much will mezzanine flooring add to the value of my warehouse?

That depends on the specific scale of the mezzanine, its use and features, and local market conditions.

For questions about mezzanine flooring, or to explore options for increasing your facility’s operational space, call Rack-Master now on 01422 300 644 or contact us

Need more storage space? The answer isn’t always to move to larger premises…

As a warehouse fills up, things can start to become more difficult to control. Safety becomes more difficult to maintain. Products can be damaged (or lost) as operations become stretched to breaking point. Picking and loading times can be compromised as picking routes become congested and products are more difficult to locate.

At times like this, it’s natural to start looking at additional or alternative premises, ones that can give you all the storage space you need plus room to manoeuvre. Ultimately, a growing business will eventually need to move to a larger warehouse, but the longer you can delay that day, the more you’ll save – IF you can make the existing facility cost efficient.

There are storage and operational options that can delay that expense until you are ready to proceed.

Use the vertical space

Most warehouses have vertical space they can use to better advantage. There are many different solutions available from high rise shelving, mezzanine floors, multi-tier shelving systems, vertical carousel systems etc. At Rack-Master we have the skills and experience to offer you the best advice on which solution is best for you and your budget.

Change the storage system

There are many ways to improve the use of the warehouse footprint, by introducing dense storage systems, changing the MHE and reducing aisle space or by using the overhead empty space above ground floor only operations. All of these are the types of projects that we carry out on a regular basis for many of our clients and we would be very interested in undertaking for you.

Talk to RACK-MASTER now about reviewing your warehouse storage installation. We’ll be able to make your storage system more efficient – whatever the size of warehouse. Call us now on 01422 300 644 or contact us

There are different solutions available to increase the use of overhead space, including mezzanine floors, multi-tier racking / shelving based systems and high rise shelving to name a few. Please contact us to discuss your needs and arrange for a free site survey.

‘Our customers are our highest priority’. Every business says it – or something like it. But how can your warehouse storage system help show it?

Expanding range

Choice is a huge factor in customer service, but the greater the choice you offer, the larger your storage space needs to be. Yet that increased storage space need not automatically mean expanding the physical space. The right pallet racking system can help you do more with less, enabling you to carry more stock by reconfiguring your industrial racking.

Protecting quality

The journey to an efficient warehouse storage system usually begins with pallets stored haphazardly on the floor. As the business grows, so does the requirement to use your storage space more effectively. But whether pallets are ‘stored’ on the floor or on legacy racking systems, an unsuitable storage system can damage products.

The right industrial storage system, on the other hand, will eradicate crushing, will protect products from snags and scuffs and forklift collisions, and will ensure the product leaves the warehouse in the same condition it arrived.

Protecting perishables

When your products include perishables, tight stock control is essential to ensure customers enjoy the freshest, finest quality. Rigorous stock control can be extremely difficult to maintain when your pallet racking system doesn’t support it. Choose a basic first in, last out system and you’re likely to waste a lot of time shuffling pallets to reach the stock that needs distributing soonest.

But with the right pallet racking management system, you can ensure no perishables are left at the back of the racks and make accessing them easy.

Responding to demand

When your customers have peak seasons you need to be able to respond. An inflexible warehouse storage system makes this difficult, But the right pallet racking system can give you the flexibility to improve picking speed, flexibility and storage capacity when the need arises.

What do your customers expect from you? We’ll help ensure your pallet racking can deliver it. Talk to RACK-MASTER now on 01422 300 644 or contact us

Before you launch straight into a pallet racking redesign, an inventory check could help you identify slack within the existing storage system.

On the face of it, it’s a simple calculation. You know when you need more storage space because you’ve reverted to storing pallets on the floor, or because picking and loading has become far too complex and time consuming as you shuffle pallets around.

In reality however, inefficient picking or no free rack space isn’t automatically a sign that you need more storage space. It could simply be a sign that you need to take another look at the things you store and how you store them. That’s where a racking inventory check can help.

What is a racking inventory check and how can I perform one?

Large warehouses simply can’t operate without an efficient way of recording what comes into the warehouse, what gets stored (and where) and what leaves. There are, of course, multiple ways of tracking pallet movements – from barcoding and scanning each unit (fine in low volume facilities), to automated SKU tracking systems.

But even the most efficient warehouse has the occasional product that somehow evades scanning, the part pallets or the random products that escaped their pallet wrap. For less technologically advanced pallet racking facilities, it’s common to find old stock growing older as it sits unnoticed in out of the way bays.

It’s especially for those businesses using traditional racking and little tracking software that an inventory check can be so vital in examining the state of rack space.

Logging everything that comes in and goes out of the warehouse – and the locations which those products occupy – can help you identify the stock that doesn’t move and the parts of the warehouse that are rarely visited. You can use the data to create a virtual ‘heat map’ of the warehouse, and then investigate the ‘cold spots’, to find why a particular area is less well used than another.

It’s not just old stock that the inventory check can reveal. It can also identify bottlenecks and areas of the warehouse that are difficult to navigate. It can help identify the products that don’t sell. And it can highlight loading or picking problems that, if resolved, could make things much more efficient.

If you’d like to find out more about pallet racking inventory checks, or want help in making your industrial warehouse storage more efficient, talk to us now on 01422 300 644 or contact us

5 key considerations before you call your industrial racking supplier.

Any overhaul of your industrial racking system is going to be a significant project, but you can minimise disruption, maximise benefits and reduce the installation time when you consider answers to the following questions:

Why change your warehouse storage?

The typical driver for a change or expansion in warehouse storage capacity is space. But your industrial racking system could do far more than increase the volume of pallets you can store. With the right design approach, you could improve picking and loading efficiency, reduce accidents, simplify stock control and make the simple process of accessing large small, pallet based and other stock so much simpler.

So consider not just the volume of space you need; look at the inefficiencies in your current operation too and ask your industrial racking supplier to suggest improvements.

Industrial racking budget

A natural consideration, but one which your warehouse storage system supplier could help you with. When bought from a reputable supplier (RACK-MASTER, for example, is a racking damage survey specialist so knows precisely which industrial racking to buy), it doesn’t have to mean compromising on safety or quality.

What’s staying and what’s going?

Another way of controlling the budget is to recognise the parts of your warehouse storage system that work and work around them. If, for example, your forklifts are virtually new, we can work with you to achieve the pallet racking system that can accommodate the forklifts most effectively.

The law relating to racking systems

From the pallet racking itself to the building works required to install the racking safely, there are legal compliance issues at every stage of your industrial racking’s design, installation and maintenance. So choose a pallet racking specialist that will ensure your business is entirely compliant with SEMA, HSE and Building Regulations requirements.

The warehouse racking contractor

The final consideration is the racking contractor. Bear in mind that there’s far more to industrial racking installation than the racking itself. A new warehouse storage system could require building works, new partitions and firewalls. You may find greater efficiency from installing a mezzanine floor, coil, roll or cantilever racking. A new layout may require the sprinklers or lights to be moved. And if you’re not sure whether your industrial racking design is going to maximise your efficiency, you’ll need a racking specialist who can advise you accordingly.

RACK-MASTER is a turnkey warehouse storage systems specialist. From concept and design to supply, installation and maintenance, we’ll ensure every aspect of your system is optimised for efficiency, safety and value.

To talk about your industrial pallet racking call us now on 01422 300 644 or contact us

5 things we’ll need to know in order to create a warehouse racking system that’s ideal for your business.

Ask us to design and supply your pallet racking system and we’ll typically need several standard pieces of information to enable us to put together a realistic estimate. Usually we’ll gather that information on a site survey, but often we can put together an estimate using information over the phone or via email. Here’s the information we’ll need to do that:

1. Space

We’ll need to know the length, height and width of your warehouse space. If the ceiling is pitched, knowing the minimum and maximum height would also be useful.

2. Weight and size

What sort of weights and loads will your industrial racking be expected to handle? Knowing this can help us create a racking system that has all the capabilities you need without over-engineering for weights you don’t need.

3. Function

What will your racking be used for? Our clients are frequently surprised by the sheer range of racking available and it may be that, where you anticipate one form of pallet racking as being the only option, we can present several more.

If, for example, you are storing drums or coils, or storing lengthy materials, cantilever racking or a coil rack could protect the products and enable more efficient loading and picking.

4. Picking and loading

Storage capacity is one key measurement of success for any warehouse racking system, but maximising storage at the expense of increasing load and pick times is a false economy. The form of picking and loading you choose will be influenced by a number of factors – including the nature of the product, whether it is perishable, the space available, the forklifts available etc. The key is finding the optimal balance between the above factors, efficiency and…

5. Budget

Even a ballpark figure can help us understand the nature of the project and understanding your budget will also help us achieve the right balance of picking and loading efficiency.

A larger budget, for example, may open the possibility of some form of automated shuttle racking to create maximum efficiency from your pallet racking space.

Don’t have the information to hand? That’s ok. Just call us now on 01422 300 644 or contact us to arrange your site survey.

Damage to your warehouse racking can be costly to repair and, if left unchecked, can risk greater damage or collapse. But by installing racking protection you can insure any impacts affect the guards and bollards, not the racking.

Pallet racking protection is an integral part of industrial racking system design. In the warehouse environment, bumps and bangs from forklifts and pallets are virtually unavoidable, but the right protection can ensure that guards, bollards and barriers take the brunt of the impact, protecting the structure behind them.

And if your racking protection suffers too great a degree of damage, replacing them is far simpler and inexpensive compared with replacing sections of warehouse racking. There are a number of racking protection measures you could choose, and when you design your industrial storage with us, we’ll help you choose the right features for your system, and ensure the design incorporates the additional space to accommodate protection whilst still giving your forklifts room for manoeuvre.

Pallet racking protection measures can include:

Rack end protection barriers

Barriers at the the rack end can provide protection at one of the most vulnerable parts of the system and ensure neither the racking nor the pallets on it suffer damage. Available in tubular or heavy duty beam-style construction.

Floor mounted column guards

Column guards can be steel or foam-filled and protect the vertical sections of racking. Bolted to the floor, the guards are designed to take the impact of warehouse machinery so the racking column doesn’t have to. Easy and cost effective to replace if damaged.

Warehouse safety bollards

Brightly coloured bollards can be used to ‘fence off’ areas of the warehouse, direct traffic away or towards certain areas and protect vulnerable structures including pallet racking.

Warehouse lighting

Easily forgotten, but the lighting in and around the aisles of your pallet racking can be essential in eliminating shadows and increasing overall light levels so warehouse operatives can see clearly. Rack-Master’s pallet racking installations can include full warehouse lighting redesign.

Call RACK-MASTER now on 01422 300 644 or contact us to explore the pallet racking protection measures for your business.