A common issue warehouse and yard managers handle from all over Northern Ireland is Long, awkward, and heavy stock. The stock types include timber, metals, pipes, and tubing, which do not take to pallets and lead to haphazard storage in racking systems. When trying to place these types of stock in standard pallet racking bays they can overhang and create visibility problems, putting both employees and the stock at risk. This is exactly the problem that heavy duty cantilever racking solves, but not all systems are designed the same, with some looking functional on paper, but failing on the ground.
The principle of cantilever racking goes like this: vertical columns are unobstructed by any front supports or cross members and offer free access from the front. This means stock can be added or removed from the front without obstruction, unlike traditional rack systems which have part shelves. It’s imperative for businesses that deal with large amounts of stock on long materials.
Adding weight to the racking system makes the entire operation more complex. Standard cantilever systems work well for lighter loads that might include PVC pipe or plasterboard. However, duties often require arms and columns to be rated for several tonnes per bay. This is where heavy-duty cantilever racking comes into play. The uprights are made from thicker steel, base plates are designed to spread the load more effectively, and the arms are deeper and reinforced to avoid bending from sustained weight. The most common mistakes made involve not obtaining the proper specifications for the racking system. Usually, businesses stock more than what the racking system is designed to hold.
To obtain the best racking system, an honest evaluation of the actual load should be performed. This includes an estimate of the single heaviest item that is going to be stored, as well as leaving a margin for safety. The height of the columns, width of the arms, and number of arm levels should all be designed around these parameters. If there will be items of considerable height that will need to be removed, the height should compensate for that. Also consider if a single-sided or double-sided design will better suit your needs. A double-sided configuration will allow for a much larger storage capacity, but only if there is room for handling and unloading equipment on either side.
Cantilever systems load the ground differently compared with other types of racking systems. This is due to the narrower footprint on which a load is supported versus a standard pallet racking frame. The base plates on which this system is supported must be sized correctly and installed properly. Attention must be paid to drainage and surface stability for outdoor installations. Standing water or uneven surfaces can compromise even the best-designed systems over time.
Once installed, inspection and maintenance should be routine, rather than an afterthought. Heavy-duty cantilever racking systems are exposed to unique challenges because they are often racked outdoors. They are subject to contact from forklifts, the elements, and repeated cycles of loading and unloading. These conditions can cause deflection in arms, columns, or corrosion which may not be so obvious from a casual glance or inspection. For this reason, an inspection and maintenance program that is aligned with SEMA standards and conducted after any sort of impact is the best way to prevent injuries and accidents.
The racking system is critical to the safe and efficient handling of long and bulky products, including structural steel and sawn timber. It is recommended that anyone looking to improve the efficiency of their operation consults specialists. This is especially true if a system of lighter storage elements has been assumed to be capable of handling heavier items.
Rather than designing only for today’s stock profile, it would make sense to consider future capacity as part of any specification decision. Businesses that grow their product range or take on heavier lines often find themselves having to retrofit racking within a couple of years as their original system was sized too tightly. It is typically much more cost-effective to do a modest allowance in the beginning, whether this be deeper arms, an additional column, or more load levels, than it will be to do a complete reconfiguration down the line. Getting the specification correct the first time is the deciding factor on whether racking becomes an operational asset, or becomes a problem that needs to be solved repeatedly.