This new construction project focused on designing a pallet rack system with modified beam heights to support efficient daily operations while keeping safety front and center. What made this installation unique was the use of punched steel deck in place of traditional wire decking for part of the project. The smaller openings created a more solid surface for hand stacking and consistent load support. The layout was carefully planned to balance access and storage capacity, using new Interlake pallet rack paired with punched steel decking. A specialized post protector was added to prevent interference with the beam.
Additional safety features, including guard rail, end of aisle protection, and post protectors, helped protect both the rack system and the building.
Conclusion
By separating overstock pallet storage and small parts picking into two purpose-built rack systems, the customer created a safer and more efficient warehouse layout. The use of punch decking in the 8-foot-tall picking area provided the stability required for small parts handling, while the 18-foot-tall pallet rack area maximized storage capacity using traditional wire decking.
This application-specific design allowed the customer to improve fulfillment speed, enhance safety, and make better use of available space without unnecessary cost or complexity.
