Industrial Racking: Does Your Business Need It? 

What Is Industrial Racking? 

Industrial racking is a larger class of heavy-duty storage systems used in warehouses, factories, and other industrial environments. It includes pallet racking and other storage techniques, such as shelving, mezzanines, and bulk storage racks. 

Where Is Industrial Racking Used? 

• Factories and production plants – Stores raw materials, tools, and machine parts. 

• E-commerce warehouses – Organizes a mix of palletized and manually picked items. 

• Cold storage facilities – Designed to store perishable goods at low temperatures. 

• Automotive storage – Used for vehicle parts, tires, and engines. 

Types of Industrial Racking 

Various industrial racking systems exist, each intended for a different kind of storage need:  

1. Selective Racking 

• Most prevalent type  

• Provides straight access to every pallet.  

• Reasonable cost and simple installation method  

2. Drive-In & Drive-Through Racking 

• Made for high density of storage.  

• Drive-in: Single access point, first-in-last-out (FILO) system 

• The FILO (First In, Last Out) system is a storage method where the most recently stored items (last in) are retrieved first. This system is common in high-density storage setups where access is only available from one side. 

• Drive-through: Two access points, first-in-first-out (FIFO) system 

• The FIFO (First In, First Out) system is a technique whereby the oldest stock—first in—is either sold or used first. This guarantees that goods never sit too long, so preventing waste and maintaining the freshness of inventory.  

3. Push Back Racking 

• Uses inclined carts and rails.  

• Pallets are loaded from the front and pushed back  

4. Cantilever Racking 

• Applied for long and heavy objects including pipes, lumber, or steel bars.  

• No front columns, enabling simple loading and unloading.   

5. Pallet Flow Racking 

• Use wheels or rollers to move automatically pallets.  

• Works on a FIFO system, perfect for fragile goods   

6. Mezzanine Racking 

• Adds an additional level—or several levels within the warehouse.  

• Improves storage capacity without adding floor space. 

Industrial Racking Costs 

The cost of industrial racking depends on many things: 

• Type of racking – Selective racking is the cheapest, while mezzanine and pallet flow racking are more expensive. 

• Load capacity – Heavy-duty racks cost more due to stronger materials. 

• Warehouse size – Larger spaces require more racks, increasing costs. 

• Installation costs – Professional installation adds to the total expense. 

Average Costs 

• Selective pallet racking: $50–$75 per pallet position 

• Drive-in/Drive-through racking: $121.00 – $135.00 per pallet position 

• Cantilever racking: Single Sided $850.00- $1,700.00 per bay 

• Mezzanine racking: $60-$70 per square foot 

Additional costs can include installation fees, safety accessories, and warehouse layout planning. 

What Is a Racking System for Warehouses? 

A warehouse racking system is a structured storage solution designed to optimize space and improve inventory management. It allows businesses to store goods safely while keeping them accessible for forklifts and warehouse workers. 

Benefits of a Racking System 

• Maximizes storage space by utilizing vertical height 

• Improves warehouse safety by preventing clutter and accidents 

• Enhances efficiency by reducing retrieval time for goods 

• Supports heavy loads, making it suitable for industrial use 

What Is Racking Construction? 

Racking construction refers to the design and installation of industrial racking systems. It involves: 

• Material selection – Steel is the most common material used for racking. 

• Structural design – Racks must be built to handle specific load capacities. 

• Safety regulations – Racking must meet OSHA and ANSI standards for warehouse safety. 

Who Uses Industrial Racking? 

Many industries rely on racking systems to store goods, raw materials, and equipment securely. These include: 

• Retailers – Large stores and supermarkets use racking to manage bulk inventory and seasonal stock. 

• Manufacturers – Factories store raw materials, semi-finished, and finished goods on racks to streamline production. 

• Logistics & Warehousing – Distribution centers use racking to organize shipments, improving order fulfillment speed. 

• E-commerce Businesses – Online retailers need efficient storage systems to handle high product turnover. 

• Automotive Industry – Racking is used to store spare parts, tools, and vehicle components. 

• Cold Storage & Food Industry – Racks are used in temperature-controlled warehouses for storing perishable goods. 

The Right Racking System for Your Business 

Retailers (Supermarkets & Large Stores) 

• Best fit: Selective Racking, Drive-In Racking 

• Ideal for managing bulk inventory and seasonal stock. 

• Allows easy access to frequently restocked products. 

Manufacturers (Factories & Production Units) 

• Best fit: Heavy-Duty Pallet Racking, Mezzanine Racking 

• Supports heavy loads of raw materials, semi-finished, and finished goods. 

• Maximizes storage space without disrupting production workflows. 

Logistics & Warehousing (Distribution Centers) 

• Best fit: Drive-Through Racking, Push-Back Racking 

• Organizes shipments efficiently for faster order fulfillment. 

• Improves storage density while keeping products accessible. 

E-commerce Businesses (Online Retailers & Fulfillment Centers) 

• Best fit: Carton Flow Racking, Mobile Racking 

• Designed for fast-moving inventory and high turnover. 

• Speeds up picking and packing processes to meet customer demand. 

Automotive Industry (Spare Parts & Tools Storage) 

• Best fit: Cantilever Racking, Shelving Systems 

• Stores long, irregular-shaped items like pipes, beams, and vehicle components. 

• Provides easy access to parts for efficient repairs and production. 

Cold Storage & Food Industry (Perishable Goods Storage) 

• Best fit: Drive-In Racking, FIFO Live Pallet Racking 

• Maximizes space in temperature-controlled environments. 

• Ensures proper stock rotation to keep food fresh and minimize waste. 

Who Can Operate a Forklift? 

Operating a forklift isn’t something anyone can do. It requires proper training and certification to guarantee workplace safety and efficiency. 

Forklift Certification Requirements 

• Training Required – Only trained and certified operators are legally allowed to operate forklifts. 

• OSHA Regulations – In the U.S., the Occupational Safety and Health Administration (OSHA) requires forklift operators to complete an approved certification program (OSHA Standard 29 CFR 1910.178). 

• Workplace-Specific Training – Operators must be trained on the specific type of forklift they will use and the warehouse environment they will work in. 

Where to Get Certified to Operate a Forklift 

Forklift certification programs are available through: 

1. OSHA-Approved Training Providers – Many organizations offer OSHA-compliant forklift training, including: 
   • National Safety Council (NSC) 
   • Occupational Safety Training Institutes 
   • Forklift training centers and schools 

2. Community Colleges & Trade Schools – Many technical schools and community colleges offer forklift certification programs. 

3. Online Forklift Training Programs – Some OSHA-compliant training programs are available online, but practical, hands-on evaluation is still required. 

4. Employer-Sponsored Training – Many employers provide in-house forklift training tailored to their specific warehouse setup. 

Why Proper Training Matters 

Untrained forklift operations can lead to accidents, injuries, product damage, and even warehouse-racking collapses, which we will see ahead.  

Certificate guarantees that: 

• Safe navigation through aisles and storage areas. 

• Proper loading and unloading techniques. 

• Awareness of forklift weight limits and stability principles. 

• Compliance with OSHA and workplace safety regulations. 

What’s the Difference Between Shelving and Racking? 

Shelving and racking are both used for storage but serve different purposes: 

Feature	Shelving	Racking
Usage	Small-scale storage, often for hand-loaded items	Large-scale storage for palletized goods
Load Capacity	Lighter loads (hundreds of pounds per shelf)	Heavy loads (thousands of pounds per rack)
Height	Typically lower (5–10 feet)	Can be much taller (up to 40 feet or more)
Access	Items accessed manually	Designed for forklifts and material handling equipment
Common Applications	Offices, small storage rooms, retail stores	Warehouses, manufacturing plants, distribution centers

How Much Weight Can Industrial Racking Hold? 

Industrial racking is designed to support thousands of pounds per rack level. But weight capacity depends on factors like material strength, rack design, and manufacturer specifications. 

Load Capacities 

• Selective Racking: 2,500–6,000 lbs per beam level 

• Drive-In Racking: 1,500–4,000 lbs per pallet position 

• Cantilever Racking: 2,000–5,000 lbs per arm (varies based on column strength) 

• Heavy-Duty Racking: 20,000+ lbs per bay 

Warehouses have to comply with OSHA and ANSI guidelines, conduct frequent inspections, and stay under manufacturer load limits to guarantee safety.  

How Pallet Racking Works 

Pallet racking is a method of storage whereby palletized goods are held using horizontal beams and upright frames. Pallets from varying rack levels are loaded and unloaded using forklifts.  

Components of Pallet Racking 

1. Upright Frames – Vertical columns that support the structure. 

2. Beams – Horizontal bars that hold pallets. 

3. Wire Decking (Optional) – Prevents pallets from falling through. 

4. Braces & Baseplates – Provide structural stability. 

Top 10 Companies in the North American Industrial Racking System Market 

Confused about which industrial racking company to rely on? Let’s clear –  

1. Steel King Industries, Inc. 

• They serve industries in manufacturing and retail. 

• They are known for pallet racks, cantilever racks and steel containers. 

• They also offer customizable solutions and are known for their durability. 

2. Ridg-U-Rak, Inc. 

• They are one of the largest pallet rack manufacturers in North America. 

• They mainly specialize in push-back systems. 

• They offer customizable options for storage systems. 

3. Interlake Mecalux 

• Known for warehouse storage solutions. 

• They offer racking systems, automated warehouses, and software solutions. 

4. SSI SCHAEFER 

• They provide sustainable, high-quality industrial racking systems. 

• They serve industries in e-commerce and manufacturing. 

5. Hannibal Industries 

• They are known for their premium carbon and stainless-steel pallet racks. 

• They mainly provide for retail and food storage sectors. 

6. UNARCO Material Handling, Inc. 

• They offer selective, cantilever and push-back systems 

• They are known for their custom designs and great customer service. 

7. Frazier Industrial Company 

• Frazier is known for steel racking systems. 

• They are known to provide high-capacity storage options and cold storage environments. 

8. Advance Storage Products 

• Mainly serve industries like manufacturing, retail, and food distribution. 

• Known for its push-back rack systems. 

9. Speedrack Products Group, Ltd. 

• Speedrack provides customizable solutions and is known for its durability. 

• They have modular designs while keeping in mind to use the warehouse to its full potential.  

10. CONCOA Storage Solutions 

• Trusted by industries like energy, healthcare, and manufacturing. 

• Known for its gas management storage rack systems. 

How to Install Industrial Racking 

Installing industrial racking requires proper planning for stability and safety. 

Step-by-Step Installation Guide 

1. Site Preparation 
   • Measure the warehouse space. 
   • Check floor conditions and load capacity. 

2. Mark Layout 
   • Follow a warehouse racking plan to optimize space. 
   • Ensure aisles are wide enough for forklifts. 

3. Assemble Upright Frames 
   • Secure frames to the warehouse floor. 

4. Install Beams & Decking 
   • Attach horizontal beams to the uprights. 
   • Add wire decking or pallet supports if needed. 

5. Secure Racks & Perform Safety Checks 
   • Anchor racks to prevent tipping. 
   • Inspect for stability before loading pallets. 

(Source: OSHA Warehouse Safety Guidelines) 

How Long Does Warehouse Racking Last? 

• The lifespan of warehouse racking depends on various factors, including material quality, load capacity, frequency of use, and maintenance practices. A well-maintained racking system can last for decades, ensuring safe and efficient storage for warehouses, distribution centers, and manufacturing facilities. 

Lifespan of Warehouse Racking 

Type of Racking	Expected Lifespan	Factors Affecting Durability
Standard Steel Racking	10–20 years	Proper load distribution, regular inspections, and minimal impact damage.
Heavy-Duty Racking	20+ years	Made from high-gauge steel, designed for high-capacity loads.
Used Racking	5–15 years (varies by condition)	Previous wear and tear, rust, or structural damage can shorten lifespan.

Factors That Affect Racking Longevity 

Several factors influence how long warehouse racking will last: 

• Material Quality – Higher-quality steel and corrosion-resistant coatings improve durability. 

• Load Capacity & Weight Distribution – Overloading racks beyond their capacity can cause bending and structural failure. 

• Environmental Conditions – Warehouses with high humidity or temperature fluctuations may cause rust or weaken metal components. 

• Impact Damage – Forklift collisions and improper loading/unloading can weaken racks over time. 

• Regular Maintenance & Inspections – Identifying early signs of wear, loose bolts, or misaligned beams can extend the lifespan of racking. 

(Source: ANSI RMI Standards) 

Safety Measures for Industrial Racking  

1. Follow Load Limits 

Every racking system has a maximum weight capacity set by the manufacturer. Exceeding this limit can weaken the structure, leading to deformations or even a total collapse. Always check weight specifications before loading, and ensure each shelf is used within its designated capacity. 

2. Distribute Loads Evenly to Prevent Instability 

Heavy items should always be placed on lower shelves, with lighter loads stored above. This lowers the system’s center of gravity, reducing the risk of tipping. Uneven weight distribution can cause the rack to lean or fail under stress, especially in seismic-prone areas. 

3. Conduct Regular Inspections 

Routine inspections should be a non-negotiable part of warehouse management. Check for: 

• Bent uprights or cross beams – Indicate impact damage, often from forklifts. 

• Missing or loose bolts – Weakens structural integrity. 

• Signs of overloading – Deflections in beams or shelves mean the rack is under too much weight. 

• Cracks in the floor or base plates – Could signal shifting or improper installation. 

A structured maintenance plan, following OSHA and ANSI RMI (Rack Manufacturers Institute) standards, is critical for keeping racks in safe working condition. 

4. Protect Racking Systems from Forklift Damage 

One of the most common causes of rack failures is forklift collisions. To minimize damage: 

• Install guardrails and column protectors at high-impact zones. 

• Clearly mark racking aisles with floor tape and safety signs. 

• Train forklift operators to navigate aisles safely and avoid sharp turns near racks. 

Forklift-related rack damage can go unnoticed, especially in fast-paced warehouse environments, making protective barriers a must-have investment. 

5. Train Employees in Proper Handling & Storage Techniques 

Even the strongest racking system won’t last long if warehouse staff aren’t trained in safe usage. Proper training should cover: 

• How to correctly place and remove pallets. 

• How to inspect racks for early signs of wear or damage. 

• Why climbing or stepping on racks is a safety hazard. 

• Emergency response protocols for racking collapses or equipment malfunctions. 

An OSHA study found that many racking failures could have been prevented with better worker training and enforcement of safety policies. Warehouses with well-trained employees see fewer accidents and lower repair costs over time. 

Rack Collapses and Forklift Accidents  

A warehouse or distribution center relies on industrial racking and forklifts to store and transport materials efficiently. But when safety measures are not strictly followed, these forklifts can become serious hazards. Rack collapses and forklift accidents not only pose a significant risk to worker safety but also lead to financial losses, legal liabilities, and operational downtime. 

The Impact of Rack Collapses 

Rack collapse is one of the most catastrophic events that can occur in a warehouse. It can result in serious injuries, fatalities, and extensive property damage. The Occupational Safety and Health Administration (OSHA) lists rack collapses among the top 10 causes of warehouse accidents in the United States. 

• Financial Costs – Rack collapses lead to an estimated $36 billion in damages annually due to injuries, lawsuits, lost productivity, and equipment replacements. 

• Operational Disruptions – A single rack failure can halt warehouse operations for days or even weeks, causing delays in shipping and lost revenue. 

• Workplace Injuries and Fatalities – Falling pallets and collapsing racks pose severe risks to workers, especially those operating forklifts or working near storage areas. 

Why Do Rack Collapses Happen? 

There are several reasons why warehouse racking systems fail: 

1. Overloading – Exceeding the rack’s weight capacity can weaken beams, leading to structural failure. 

2. Improper Installation – Racks that are not installed incorrectly are more likely to collapse. 

3. Forklift Impacts – Accidental collisions with racks can compromise their integrity, increasing the risk of failure. 

4. Poor Maintenance – Rust, missing bolts, or bent beams can weaken the structure, making it more susceptible to collapse. 

5. Uneven Loading – Stacking products improperly creates imbalances, putting excessive pressure on certain areas of the racking system. 

Forklift Accidents 

Forklifts are essential for material handling but are also one of the leading causes of workplace injuries and fatalities. According to OSHA’s latest reports: 

• 75 to 100 workers are killed in forklift-related accidents every year. 

• Forklift-related deaths have increased by nearly 30% in the last decade. 

• Between 35,000 and 62,000 injuries occur annually due to forklift incidents. 

• Forklift overturning accounts for 25% of all forklift accidents, making it the most common type of incident. 

Frequent maintenance and repairing your forklifts will help you prevent dangerous damage.

Types of Forklift Accidents 

1. Overturning – When a forklift tips over due to excessive speed, improper loading, or sudden turns. 

2. Collisions with Racks or Workers – Forklifts can strike shelving units or personnel, leading to serious injuries. 

3. Falling Loads – If products are not secured properly, they can fall from high racks, endangering nearby workers. 

4. Pedestrian Accidents – Poor visibility and lack of traffic control in warehouses increase the risk of forklifts hitting workers. 

The Role of Slip and Fall Accidents 

Slip, trip, and fall incidents are another major safety concern in warehouses. According to the U.S. Department of Labor: 

• These accidents make up 15% of all accidental deaths in industrial workplaces. 

• They account for 25% of all injury claims in warehouses. 

• Every year, workers lose 95 million workdays due to slip and fall injuries. 

Slippery floors, loose materials, poor lighting, and uneven surfaces are common hazards contributing to these incidents. 

Racking Problems  

Even a well-built racking system will experience wear and tear. Catching issues early can prevent structural failures that lead to product loss or injuries. 

1. Bent or Damaged Uprights 

Overload, forklift impacts, even small changes over time can cause uprights to bend. A bent upright lowers the weight-bearing capacity of a rack and raises the likelihood of a collapse. Any damage—even minor—should be taken care of right away; racking components are not made to “bend back” safely.  

2. Rust and Corrosion 

Rust development can compromise metal components in humid conditions or in warehouses handling corrosive materials. Because rusted racks lose structural integrity, they are more prone to break under loads. Frequent application of protective coatings and rust inspection help to increase the lifetime of a racking system.  

3. Loose or Missing Bolts 

Although bolts maintain the integrity of the construction, daily operations and forklifts can cause vibrations that over time loosen them. Missing or loose bolts compromise stability, so raising the possibility of rack failure. A brief weekly bolt check can stop significant down-stream failures.  

4. Improper Loading 

Loading racking systems such that weight is distributed equally is crucial. Among common errors are:  

• Higher tipping risk results from stacking heavier objects on top.  

• Overloading single shelves results in bending or breaking of beams.  

• Pallets left half hanging off shelves might cause falls and injuries.  

• Clearly marked weight restrictions and training refresher should be available in warehouses to guarantee correct loading methods are used.  

5. Poorly Anchored Racks 

Anchoring industrial racks to the floor will help to stop shifting or collapsing. Around anchor points, loose anchors or cracked concrete point to instability. Regular floor inspections and re-anchoring when needed help to keep racks stable. 

MDS Industrial Equipment for Your Racking Needs 

MDS Industrial Equipment offers:  

• We offer competitive rates without compromising on quality.  

• Our staff guarantees correct setup and provides frequent inspections to keep your racking systems safe and effective.  

• MDS is everything you need for warehouse optimization from equipment rentals to racking design.  

• Our team of experts is always ready to help you decide on the correct racking system for your company.  

MDS Industrial Equipment has you covered whether your search is for safe and reasonably priced industrial racking solutions. Contact us now!