As more companies seek to modernize their operations, many look to replace labor intensive handling methods with automation. Yet, when swapping traditional forklifts for automatic guided vehicles (AGVs) to select and place heavy loads stored in storage rack, the current system may not support the automation optimally. To maximize the benefits of the automation, there are a few key factors to consider when integrating storage rack and AGVs.
Design Features Important When Pairing Pallet Rack and AGVs
While AGVs require a significant investment, they can deliver a substantial payoff in increased material handling efficiency. They also help improve accuracy, decrease reliance on labor, and reduce damage to racking, equipment, and structures.
To attain those benefits, however, there are several rack design factors to consider, explained Kurt Larson, Steel King Industries’ Regional Sales Manager for the central U.S. The company is a member of the Rack Manufacturers Institute (RMI).
“The racking must feature consistent access pocket locations for the AGVs to interface with it,” he said. “AGV access pocket distribution must also be even and available throughout the rack. Any damaged racking will further reduce the automation’s effectiveness.”
Additionally, automated vehicles require tight tolerances when interfacing with other systems — including storage rack. Alignment variances can impede the automation’s ability to access stored items. Overloaded rack structures, or those with bowing, sagging, or leaning beams and columns, can interfere with the ability of vehicle sensors to accurately detect obstacles.
All of these factors can make it challenging to integrate existing pallet rack and AGVs.
Engineering Rack to Support Automated Vehicles
Steel King recently worked with a metal supplier that wanted to use driverless vehicles to store and pull materials to fulfill customer orders, said Larson. The company’s switch to AGVs coincided with the construction of a new, 900,000-square-foot facility. That created the opportunity to design a new rack solution that met the exacting requirements of the automation.
“The new facility needed 18,000 storage locations to accommodate 6,000 product SKUs,” he recalled. “The rack had to hold a combined weight of 50 million pounds of carbon steel, stainless steel, aluminum, and specialty metals.”
To support the exceptionally heavy loads while maintaining the tight tolerances required by the AGVs, the racking uses structural steel cantilever I-beam construction. This allows the AGVs to access the storage rack from both sides. The cantilever racking incorporates more than 1,000 double-sided columns, more than 30,000 arms, and more than 15,000 linear feet of structural metal for guard rails, added Larson.
Precision Navigation Enables Tighter Rack Spacing
Thanks to the AGVs’ precise navigation, consistent travel speeds, and safety sensors, engineers designing rack for automation can space the rows closer together. That was the case with the metal supplier’s new facility as well.
“The racking system was able to have narrower aisles, and therefore greater storage density,” he explained. “Our engineers also designed notches in rails to guide the AGVs. That created more space dedicated to racking rather than to aisles.”
Ultimately, by implementing storage rack designed to complement the AGVs, the operation realized horizontal space savings normally lost to rack structure. They also eliminated the risk of fork truck damage and achieved for faster load and unload times, concluded Larson.
RMI Cantilevered Rack Standard Guides Design
RMI provides guidance on the safe design, manufacture, and installation of cantilevered rack in its ANSI MH16.3 Specification for the Design, Testing and Utilization of Industrial Steel Cantilevered Storage Racks. The standard applies to cantilevered racks made with cold-formed or hot-rolled steel. It also details best practices for safe use of the rack.
Designed and engineered to hold long loads, these systems feature a central, vertical column. Horizontal arms extend outward from one or both sides of the column. With no columns facing the aisle, cantilevered rack is ideal for storing steel bar stock, steel sheets, PVC piping, metal pipes and more.
Learn More About Designing Racks for Automation
RMI will present a free educational seminar at ProMat 2025. “Pallet Racking Systems and Design for an Automated Future” occurs on Tuesday, March 18. The session explains the key rack design factors that support successful automation deployments. For those who are unable to attend, a recording of the presentation will be available online after the show.
