CONVENTIONAL

PALLET

RACKING

Най-универсалната система с директен достъп до всяко пале

The most universal system for direct access to every single pallet

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CONVENTIONAL PALLET RACKING A conventional pallet racking warehouse is
generally laid out with single-entry racks either
• Universal system with direct access to every side and double-entry racks in the middle.
pallet
• Maximizes space available for storage The width of the working aisle between each
• Adaptable to any size or weight of pallet rack and the height of the racks depend on
• Increased stock control the characteristics of the forklifts or handling
• Better sevrice in the warehouse equipment, the size of the pallets and the
height of the warehouse itself.
The conventional pallet racking system offers
the best solution for warehouses where a
wide range of references need to be stored on
pallets.
The wide range of profiles and accessories
provides optimal adaptation to each load and
height requirement.

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Double-deep conventional pallet racking
In order to store a greater number of pallets (depending on their weight and the number of pallets
per reference) double-deep racks can be installed, enabling one pallet to be stored in front of another
on each side of the aisle.
Since direct access is only available for the front pallets, this system is recommended for products
with more than one pallet per reference.
This system requires suitable lifting machinery fitted with double-depth telescopic forks.

The most common conventional system made of a signle-entry rack Double-deep conventional system
fitted to the wall and double-entry racks in the middle

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 MEASUREMENTS AND CLEARANCE
Aisle Reach height and clearance
In order to define the minimum free aisle width The free height between load levels is obtained
between loads it is necessary to ascertain by taking into account the total height of the
the type and model of forklift truck. This pallet plus the load and adding this figure to the
information can be found in the technical necessary clearance. This should never be less
specifications of each forklift truck. than the figure indicated in the technical rack
As a guideline, for pallets measuring 1,200 x clearances table.
800 mm, handled by the sides of 800 mm, the Reach heights also differ for each type of forklift
following type of lift trucks are used: truck. This information can be found in the
Minimum clearances technical specifications of each forklift.
Stacker: from 2,200 to 2,300 mm Maximum height:
Counter-balanced forklift: Stacker: 5,200 mm
from 3,200 to 3,500 mm Counter-balanced forklift:
Reach truck: 7,000 mm
from 2,600 to 2,900 mm Reach truck:
12,000 mm
Bilateral turret truck:
from1 ,500 to 1,600 mm Bilateral turret truck:
13,500 mm
Trilateral turret truck:
from 1,700 to 1,900 mm Trilateral turret truck:
14,500 mm
Automatic trilateral stacker crane:
from 1,700 to 1,900 mm Automatic trilateral stacker crane:
14,500 mm
Stacker crane:
from 1,500 to 1,650 mm Stacker crane:
45,000 mm

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 THE MOST COMMONLY USED MATERIAL HANDLING EQUIPMENT

Stacker

VNA Man-up turret truck

Counter balanced forklift

Reach-truck

Automatic trilateral
stacker crane

VNA Man-down turret truck Stacker crane

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UNIT LOADS: Pallets and containers
Pallets and containers are elements where the
goods to be stored are placed. Their different
characteristics determine the way they should
be stored.
The most common types are:
Europallets
Europallets measure 800 x 1,200 mm and are
handled by their narrowest side. Perimeter base pallets
Pallets are also made using the same criteria These pallets are built in a similar way to
in sizes of 1,000 x 1,200 mm and 1,200 x ,1200 Europallets, but they have two additional skids
mm. To support them, they are built with nine on the base, which are interconnected with the
blocks and three skids along the base. other three.

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 Europallets (800 x 1,200 mm) are normally
Containers handled by the narrowest side, since they have
Containers for three skids running along the base, parallel to
storage are usually the side measuring 1,200 mm. When stored on
made of metal the racks, these skids rest perpendicular to the
and are built support beams.
with variable On occasions, particularly in order to facilitate
specifications and sizes. They may require picking work, they are handled by their wider
additional components to be used for storage side (1,200 mm). In such cases, the racks should
on conventional pallet racking. be fitted with components enabling the pallets
Other pallets and containers to be properly supported (pallet support bars).
In addition to the previously mentioned types,
other pallets and containers are also available
on the market. These require individual study in
order to ascertain the best way to store them.

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 BASIC COMPONENTS

1. Frame
2. Beam
3. Safety locking mechanism
4. Row spacer
5. Anchor bolts
6. Levelling shims
7. Upright protector
8. Lateral protection barrier
9. Cross bracing set
10. Top portal tie
11. Pallet support bar
12. Container support bar
13. Chipboard deck support
14. Chipboard or melamine shelf
15. Galvanised picking shelf panel
16. Mesh shelf
17. Drum support
18. Back stop rails
19. Fall protection mesh guarding
20. Raised pallet support bar
21. Aisle identification plate
22. Loading sign

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FRAMES
Frames are made up of two uprights with the
corresponding horizontal and diagonal bracings,
footplates and accessories. They are slotted
every 50 mm in order to fit the beams.
The depth of the frame is determined by the
size of the pallet. For a Europallet measuring
1,200 mm deep, a 1,100 mm frame is normally
used.

Uprights (1)
The different models, sections
and thickness of uprights
enable them to be adapted
to a wide range of loading
requirements.

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Frame footplates (2) Levelling shims (3) Anchor bolts (4))
Frams are erected on the floor Shims level our rackes which Rackes are fixed to the slab
using foorplates which are stand on uneven slabs. Each using anchor bolts. They vary
fitted to the base of uprtights. type of upright has its own depending on the forces they
There is a range of different type of shim which comes in have to whitstand and the
frame footplates which use different thickness allowing for characteristics of the slab itself.
depends on the load to be more precise levelling.
supported and on the upright
model to be used. They are
anchored to the floor using one
or two anchor bolts.
Footplate and shim measurements

Upright Width-mm Depth-mm cm2

80 135 119 160.60
101 155 119 184.40
122 175 119 208.20
127 175 119 208.20
A10 determined by the load

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Frame footplates (2)
The height between levels is
calculated by adding together
three variables: the pallet
height, including the load, the
beam height and the clearance
(Y). These values are rounded
up to a measurement that is a
multiple of 50 mm.

Bay tolerances and clearances:

Y: height between the pallet
and the bottom of the beam
for levels other than the
bottom level
X: minimum clearance between
pallets or loads
Dimensions in mm

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Beams
Beams are the horizontal and
robust components of the racks
upon which loads are deposited.
They are joined to the uprights
via connectors or endplates,
which fit into the slots on the
upright.
The hooks on these endplates, in the connecting Tubular beams
system are joined to the main body at both
ends. This considerably increases load capacity
and prevents deformations that typically occur
when the connection between the main body
and the hooks or endplate is not sturdy enough.
As such, our connector system reduces the
possibility of the beam falling, which could
occur if it began to prise open due to fatigue.
Each beam has two safety devices built in, to
prevent accidental dislodgement. There is a Model TB Height /A/ Width /B/
wide range of beams covering different needs
both in terms of their size, as well as load type TB 80 80 50
and capacity. The measurements of the load TB 100 100 50
levels are determined by the number and size of
the pallets stored. TB 120 120 50
TB 130 130 50

Dimensions in mm

Beams for pallets

There are eight standard models classified into
two families distinguished by the size of the
connections or endplates.

Model 2C-S Height /A/ Width /B/

1115 110 50
1315 130 50 2C-S beam-1115 2C-S beam
1515 150 50 Made up of 2 C-shaped 1315,1515,1615,1718
profiles fitted into each These beams are used
1615 160 50
other and welded to for heavy loads and
1718 170 50 the endplate. longer lengths due to
their strength.

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Shelves
Different types of shelves are available, to suit
any requirement. The most commonly used are:

L-2C galvanised shelves Galvanised picking shelves

Metal shelves which, depending on the storage A combination of metal shelf panels are used
requirements, can be placed on tubular or 2C with ZS-60 beams. The lips and flanges of the
beams. They fit directly on top of the beams shelf panels are used to fit them together to
and do not require further securing. create a full width shelf.

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Mesh shelves
Mesh shelves are made up of rectangular
electro-welded mesh supported on deck
supports, which strengthen the structure.
They are always fitted on 2C beams and do not
require further securing.

Chipboard shelves

2C Beams J or Z Beams Chipboard deck supports and

Chipboard shelves can be fitted on Chipboard shelves do not require brackets to Z TAM clamps
tubular or 2C beams, and secured be fitted on J or Z beams, as the edge of the Chipboard deck supports can be added
using four retainers. Chipboard deck shelf is hidden and supported on the beam to increase the shelf load capacity where
supports can also be used. profile. Chipboard deck supports may be required. Z beams with chipboard shelves
required depending on the load. exceeding ≥ 1,900 mm in length must be
fitted with one Z TAM clamp per beam.

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 Protectors
These protect racks from light impacts that may
occur at floor level, preventing damage to the
vertical elements.
Lateral frame protection
These protect the side of the rack at the
bottom. They are normally fitted to end frames
and in passageways between frames where
impacts are most likely. Each upright type has
its own protector. In order to protect the entire
side of a frame, two upright protectors and one
C profile are used. Two C profiles can also be
fitted if the client requires.

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Upright-frame protector Corner protectors Upright reinforcer
Each type of upright has These protect the outer If the uprights of an installation need
its own type of protector. uprights when it is not to be protected at a certain height,
They are 400 mm high and possible to fit upright and it is not possible to fit an upright
come with 4 anchor bolts protectors. They are made protector, an upright reinforcer is used
to fix them to the floor. from 400 mm high folded which is fixed directly onto the upright
They are used to protect metal sheets. They have instead of the floor. Upright reinforcers
uprights from impact four holes in their base for are made from wedgeshaped folded
and possible damage in bolting the component to sheets and have holes along their sides
facilities where forklift the floor. so they can be fixed to the upright.
trucks operate. Upright reinforcers are available in
different heights for each type of
upright.

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 Close-up of a galvanised pallet support

Pallet and container supports

Depending on how the pallet or container is
placed on the rack it may be necessary to add
extra support to the beams, such the following
pallet or container supports.

Raised pallet supports

These are necessary when storing
Galvanised pallet supports pallets without skids.
These are fitted perpendicular to the beams
and are used to provide support to pallets
when they are placed on the rack with the
lower skids parallel to the beams or when the
pallet quality is insufficient. Two are needed
for each pallet.

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Container support
This component is fitted when containers
with legs instead of skids are stored on racks.
Two supports are used per container, one on
the right and one on the left. The container
supports can be fitted with end-stops which
are bolted to the back of each support.

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 2L Cylinder support Roller drum support Front drum support
This set is made up of two Made up of two rollers These are metal sections which are
L-shaped profiles joined by on which the drums turn, fitted to the 2C beams, allowing the
two front profiles which enabling liquid to be storage of drums. A drum support is
form a cradle, allowing the extracted from them. A tray placed horizontally on the each beam.
secure placement of the below prevents the liquid The V shape provides the necessary
cylinder. They are fitted from spilling onto the floor. support to hold drums and reels in
across the beams. place.

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Reel supports
Reel supports enable
cylindershaped articles
to be stored on a metal
axle (cable reels and
paper reels, etc.). Two
systems are available;
front storage and side
storage, depending on
the characteristics of the
goods, their sizes and their
use. Support axles and
collars are available as
accessories. They prevent
the reels from slipping
sideways.

Front reel support Side reel support Support axle and collars
The front reel support is The side reel support is The axle is tubular with a diameter
fitted to the front uprights fitted laterally on to the of 60 mm and is available in different
of the frame, where it is frame using bolts and is thicknesses. It is used as an axle on
simply slotted into the used to position the reel on which the reels can rotate, resting
upright slots. the centre of the frame. directly on the supports. Conical-
shaped adjustable collars can be used
as end-stops to prevent products from
slipping along the axle.

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Safety features
Complementary elements to
make installations safer, and
prevent goods or pallets from
falling.
The following elements are
available:
1. Positioning profile
2. Safety profile
3. Fall protection mesh Positioning profile Safety profile
Located on the top of the Works as a warning system,
4. Protective mesh in the
rack in such a way that preventing a pallet from falling. In
passageways
ensures the pallet (not the this case, it does not need to resist
load) is in constant contact pallet movement stresses or serve
with said profile. This must as a brake system for intended
resist stresses from pallet manoeuvres. In this system, the
positioning, and therefore, load (not the pallet) is what butts
the rack must be designed up against the safety profile.
to withstand them. This accessory serves as a safety
mechanism to prevent potential
falls or collisions of load units
that might result from improper
manoeuvring of the handling
equipment.

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 Fall protection mesh
When the load is not shrinkwrapped or it is
possible that the safety profile might not be
enough to prevent the goods from falling,
fall protection mesh can be installed. This is
an optional safety element which is fitted at
the back of racks, where there is a danger
of loads falling. They can cover all or part of
the racking height. If a single rack borders on
a work or traffic area, it must be protected
with a net to prevent materials accidentally
falling, becoming trapped, etc.

Protective mesh in the passageways

An alternative way of increasing warehouse
safety and protecting people working in
the passageways found in the lower levels
of the racking (tunnels), is to fit them with
protective mesh along the top. By doing so,
warehouse operators moving around the
passageways will not be hit by objects that
become inadvertently dislodged from the
upper levels of the racks.

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Cross Bracing
Cross braces are flat profiles
fitted to supports which in
turn are fixed to the frames.
Each profile has a tensioner
which gives it the necessary
rigidity. They are used to
increase down-aisle stability
when the height and load
make this necessary in the
installation.

Close-up of the brace rail bracket

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GENERAL FEATURES OF HIGH-BAY
PALLET RACKING SYSTEM

These warehouses are made up of high

bay racks separated by narrow storage
aisles.The main advantage of these
warehouses is their excellent use of
space and their direct access to any
stored pallet.

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Turret trucks
Turret trucks are designed to work in narrow aisles, generally with high bay racking. These machines
need to be guided when operating inside load lanes.
Outside the load aisles, the vehicles are slow and so most of their work is done within these aisles.
They are often supported by more conventional handling devices which help by depositing and
picking up pallets at the end of the racking aisles. Turret trucks can be classified into two different
systems:

Man-up system (Class 300 A) Man-down system (Class 300B)

The driver of the truck sits This system is characterised by
inside the cabin which moves up the use of a truck in which the
and down with the goods. This driver‘s cabin remains immobile
enables greater manoeuvrability while the goods are moved up
and allows the operator to pick and down.
directly from the pallets.
This system is also known as
combi, as both pallet storage
and picking work can be
combined.

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Types of forks
Goods can be extracted with two types of forks: trilateral and bilateral.

Trilateral forks Bilateral fork

Trilateral forks enable pallets to be picked Bilateral forks can only pick up and leave
up from and deposited on the floor in three pallets in a raised position and so cannot pick
positions: from the front, and from either them up directly from the floor. Installations
side of the truck via a rotating swivel carriage will be taller and aisles narrower.
head.

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Guidance systems for turret
trucks
Turret trucks must be guided
along the inside of storage
aisles. These vehicles can be
wire-guided, in which case a
wire is embedded into the floor,
giving off a magnetic field to
guide the truck‘s movement,
or mechanically guided, using
profiles which are fitted to both
sides of the aisle, and anchored
to the floor.
Each vehicle model functions with
a different type of guide rail and
aisle width. The distance between
guide rails and the distance
between load pallets must be
defined in the aisle width.

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Guidance with LPN 50 profile Guidance with UPN 100 profile Guidance with UPN 100 profile
The pallets are supported The pallets are supported on forming concrete platform
directly on the floor. proflies fitted onto the floor or The space between the guide
on the beams. rails under the racks is filled
in with concrete. The racks
are built on top of concrete
platform.

In the aisle entry with mechanical guidance entry

profiles are fitted with guidance entry rails in
order to help contre the vehicles.
Wire guidance
A wire embedded into the
floor produces a magnetic field
which guides the vehicle.

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Pick-up & Delivery stations
P&D stations are installed at the rack ends in order to deposit the pallets temporarily. These are
commonly used in narrow aisle systems.
Turret trucks, designed fundamentally to work inside the aisles, pick up and deposit the pallets on
the P&D stations. Other more conventional fork-lift trucks then handle the pallets from this point.
A number of different P&D stations are available. They have been designed to cover different
need, depending on quantity in height, sizes, loads, etc. P&D stations can also be fitted with pallet
centralisers which enable pallets to be positioned with greater precision, making it easier to place
them in locations with lower tolerance margins.
When the guidance is done mechanically, pallet support rails must also be fitted at the rack ends.

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P&D conveyor systems
In high-bay warehouses of this type,
transporting pallets from the docking area to
the rack’s P&D station can be automated. To do
this, the warehouse is equipped with roller and
chain conveyors. In some installations, shuttles
are also used. These move the pallets to and
from the rack’s entry and exit points.

Automatic trilateral stacker crane

This is the perfect solution for the
simple automation of a warehouse
with conventional racks of up to
15m high.
The stacker crane moves the pallets
to the end of the aisle leaving
the load on a rack or automated
transport system. This is possible
since it has a rotating head which
allows it to pick-up and leave pallets
in three positions: in front and at
either side.
Operation is fully automated, and
all stacker crane movements are
in response to storage or retrieval
commands sent from the control
system, which optimises its
movements.

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SAFETY ACCESSORIES
Safety passageways
For safety reasons an installaion may require ground-level passageways running through th eracks as
emergency exits.
Top portal tie
High bay racks are often connected at the top by portal ties to provide additional stability.

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 Fire-protection systems
High-bay racks are usually equipped with a
built-in fire protection system.
If such a system is installed, it is necessary
to determine the tolerances between
racks and the separation between levels
necessary for the pipes and sprinklers to be
installed.
The pipes and sprinklers should coincide
with the position at which the beams are
fitted.

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 Thank you for your attention!
We welcome your questions, you can find us at:

[email protected]

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