Engineered and constructed with upright frames and side rails upon which pallet loads of the same product are stored, the safe use of drive-in rack depends on two key pallet factors: size and structural integrity. That’s because drive-in rack allows a forklift to enter from one side of the structure to pick up or deliver pallets that rest on continuous rails. Therefore, the pallets’ sizing must precisely span the distance between the two rails by resting evenly on their surfaces. They must also be intact and sturdy enough to bear the weight of their loads without collapse.
Match Drive-in Rack to Pallet
Most manufacturers design and engineer drive-in rack specifically to fit one pallet dimension, usually 40 inches wide. Therefore, the typical system spaces the vertical legs of the pallet guide angles 42 inches apart and uses 3-inch-wide pallet guide rails. This ensures that the pallet has an extra inch of leeway to accommodate placement farther to the left or the right. The additional rail width provides enough “bite” for the pallet to rest securely in place. Anything smaller has an increased likelihood of falling should the operator not center the pallet perfectly. Anything larger will impact the uprights and potentially cause structural damage or rack failure. (While wider, 4-inch rails are available, their use can increase the overall cost of the structure.)
For this reason, it is not recommended that multiple pallet sizes be used within the same drive-in rack structure. Should an operation desire drive-in racking for different pallet dimensions, best practice is to install separate rack structures designed specifically to match each pallet’s profile. In fact, some operations re-palletize received items onto an in-house pallet prior to putaway. This to ensures they always use the right size pallet in a given drive-in rack.
Pallet Integrity Critical
As for pallet integrity, it is critical to ensure that the bottom boards are intact. Pallets with cracked or broken boards are more likely to fail and collapse under the load’s weight as it rests on the rails. Upon receipt, inspect pallets prior to putaway in the drive-in rack. Re-palletize loads, removing them from damaged pallets to intact ones before storage.
To avoid these potential issues, operations using drive-in rack should conduct regular forklift operator training. Teach operators about proper loading and unloading of these structures. Operators should also know how to identify the size and condition of the pallets before placing them within the storage system.
Want more best practice ideas for the safe operation and use of industrial storage rack systems? Download RMI’s ANSI MH16.1-2012 (R2019) Specification for the Design, Testing and Utilization of Industrial Steel Storage Racks.
