Ideal for maximizing the available cube within a facility, drive-in rack enables highly dense storage of multiple pallets of uniform product. Because it eliminates multiple travel paths and access aisles, drive-in rack can create additional pallet storage positions. This enables more effective use of a building’s footprint. Before adding such a structure to a facility, however, it’s important to keep a few considerations in mind. These include:
Drive-in rack supports a last-in/first-out (LIFO) inventory management strategy. Because it must be loaded back to front (and unloaded in the opposite manner), drive-in rack is not suitable for products that require a high degree of selectivity or picking frequency.
Drive-in rack is engineered purposely to accommodate counterbalanced forklifts matching certain dimensions with appropriate clearances between columns, under rails, and between baseplates. Using a larger vehicle will damage the rack. Likewise, using a vehicle with fixed outriggers for load stability, such as a straddle truck or stacker, will result in rack damage.
The dimensions of drive-in rack openings, column placement, rail width and pallet position heights are engineered to match a specific pallet width. It is also important to make sure the fork truck can fit between the rails. While typically it is recommended that only one size pallet be used within a given drive-in rack system, systems can be designed to accommodate two pallet widths. To prevent operator confusion, however, it is suggested that operations looking to use more than one pallet size with drive-in racking consider a second, separate system sized to match the different pallet. This maximizes space utilization and ensures that pallets do not fall between the rails. Additionally, only pallets with intact bottom boards (no cracks, splits or damage) should be placed within drive-in rack to reduce the risk of pallet failure under load.
Forklift operators must be trained on the proper best practices for safely loading and unloading drive-in rack. These structures require the load to be lifted to its ultimate designated position height prior to the vehicle entering the rack. Continually train drivers to enter and back out of the structure at a controlled speed. They should also drive with caution, particularly when backing into the aisle, where there is potential for a cross-traffic collision. Additionally, aisles must be wide enough to accommodate the counterbalanced forklift’s need to maneuver to a position 90° perpendicular to the rack prior to entering it.
Because drive-in rack designs incorporate upright frames, rails, and ties (but no horizontal beams except at the very top and across the back), they utilize columns and baseplates that meet specific stability and rigidity requirements. That is, they tend to be heavier and use more anchors to connect the system to the floor. Consider requesting additional protective measures designed into the front entrance columns and arms of drive-in rack. Those components are the most likely to experience an impact from forklift traffic and loads. Many manufacturers offer more robust columns and base plates. Others provide an extra flared width on the rail at the entrance point. This provides supplementary guidance in pallet positioning.
Most drive-in rack structures feature with 3-inch columns for adequate stiffness and stability. However, systems that exceed 21 feet in height should incorporate 4-inch columns for strength. The extra material can impact the overall cost of the system. In turn, however, the resulting gains in storage space may offset that expense.
Operations seeking extra-deep drive-in racking of 10 positions or more should consider a dual-entry system. These feature five pallet positions each placed back-to-back. This reduces the distance a forklift must travel into the racking to place or retrieve a load. It also lowers the risk of a column impact.
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Posted by Rafael Gonzalez on November 29,
What do you store in your warehouse? Are you looking for an even more dense storage system? Warehouses usually share one common goal—maximize space and value. Drive-in racking is one of the best pallet racking systems for maximizing space. It has potential to multiply the amount of usable storage square footage in your warehouse.
Finding the right kind of pallet racking for your warehouse can be a challenge if you don’t know the differences between each type of racking. Drive-in racking is a versatile solution and unique type of racking for warehouses and distribution facilities. Learn more about the advantages and disadvantages of drive-in pallet racking to see if it could be the right fit for your pallet storage.
Drive-in racking is most widely used in the manufacturing and food and beverage industries. This dense storage system requires much less aisle space compared to other types of racking, making it ideal for cooler and freezer applications. Use less energy with a more efficient use of your space. Additionally, for a large inventory of products with the same SKU, drive-in racks provide dense storage for non-perishable products or products with a low turnover. This is because pallets that are loaded first will be harder to access, because they slide to the back of the system over time as more pallets are loaded onto the system in front of them.
With drive-in racking, pallet racks have lanes for forklift access that essentially have an unlimited amount of depth. The most common drive-in racks are generally designed to be between 6-8 pallets deep. Having such a dense system with fewer aisles uses more space in your warehouse. Each lane enters and exits one way. Drive-in racking is constructed with side rails as opposed to a typical racking system with cross beams. The pallets sit on the rails and are loaded with a LIFO (last-in-first-out) inventory system.
Single Entry: forklift access on one side only. This is known as standard drive-in racking.
Double Entry: forklift access on both sides of racking. Double entry was designed to allow access to pallets from the back side of the rack system as well as the front. A large beam in the center of the structure holds all of the racks together. This style is called drive-through racking.
If you are interested in this dense storage system, contact one of our rack experts today to speak about installing drive-in racking in your warehouse or distribution center today.
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