All You Have to Know About Cantilever Racks

Introduction

Cantilever racking systems are an essential type of rack for storing long, bulky, or oddly shaped items such as piping, lumber, and structural steel. Unlike traditional pallet racks, roll-formed cantilever racks do not have vertical supports on the front, allowing for easier access.

Understanding how to calculate the capacity of a cantilever pallet racking is vital to ensure safety and efficiency in warehouse operations. This comprehensive guide will walk you through the process of calculating cantilever rack capacity, address common issues and solutions, and provide valuable insights into the pros and cons of cantilever racking systems.

Understanding Cantilever Racking

Cantilever racks are designed to store items that are too long or oddly shaped to fit on traditional pallet racks. The system consists of three main components: uprights, arms, and brace sets. The uprights are vertical columns that support the structure, while the arms extend horizontally to hold the load. Brace sets connect the uprights, adding stability to the system.

Cantilever racks are favored for their ability to store certain items which are hard to store on standard pallet racks. This system provides an efficient solution for managing space in warehouses, offering greater flexibility and making pallets more easy to access compared to traditional storage systems. By eliminating the vertical supports on the front, cantilever racks allow for easy loading and unloading of items, making them ideal for storing materials of various lengths and shapes.

Calculating Cantilever Rack Capacity

To ensure the stability and safety of your cantilever warehouse rack, it is crucial to calculate the capacity of the arms and uprights correctly. The capacity of each arm can be determined using the following formula:

Weight capacity per arm=Total product weight per level Required number of arms\text{Weight capacity per arm} = \frac{\text{Total product weight per level}}{\text{Required number of arms}}Weight capacity per arm=Required number of armsTotal product weight per level​

For example, if you have a product weighing 1,000 lbs and you require four arms to support it, each arm should have a capacity of at least 250 lbs. It is important to ensure that the load is evenly distributed and centered on the arms to prevent tip loading, which can significantly reduce the capacity and stability of the rack.

Steps to Calculate Arm Length and Capacity

1.  Determine the Product Dimensions: Measure the width and height of the products you intend to store. The arms should be slightly longer than the product width to ensure proper support.

2.  Calculate the Total Product Weight per Level: Sum the weight of all items stored on a single level of the cantilever rack.

3.  Determine the Number of Arms Required: Perform a simple test by placing your product on wooden blocks spaced 2 feet apart. If no deflection is observed, a standard two-arm system is sufficient. If deflection occurs, add more arms until the product is fully supported.

4.  Calculate the Weight Capacity per Arm: Divide the total product weight per level by the required number of arms to determine the capacity of each arm.

Calculating Cantilever Upright Capacity

Once you have determined the capacity of the arms, you can calculate the capacity of the uprights using the following formula:

Capacity required per upright=(Number of arms×Capacity per arm)Number of uprights\text{Capacity required per upright} = \frac{(\text{Number of arms} \times \text{Capacity per arm})}{\text{Number of uprights}}Capacity required per upright=Number of uprights(Number of arms×Capacity per arm)​

For instance, if your system uses 12 arms and each arm has a capacity of 2,500 lbs, the total capacity equals 30,000 lbs. If your system is using three uprights, then a minimum required capacity of 10,000 lbs per upright is needed.

(12 arms×2,500 lbs capacity per arm)/3 uprights=10,000 lbs capacity needed per upright(12 \text{ arms} \times 2,500 \text{ lbs capacity per arm}) / 3 \text{ uprights} = 10,000 \text{ lbs capacity needed per upright}(12 arms×2,500 lbs capacity per arm)/3 uprights=10,000 lbs capacity needed per upright

Practical Example

Let's consider a practical example to illustrate the calculation process. Suppose you need to store lumber on a cantilever shelving. The lumber pieces are 10 feet long and weigh 500 lbs each. You plan to store four pieces per level, resulting in a total weight of 2,000 lbs per level.

1.  Determine Arm Length:

Since the lumber is 10 feet long, each arm should be at least 10 feet to provide proper support.

2.  Calculate the Number of Arms:

Perform a deflection test by placing the lumber on wooden blocks spaced 2 feet apart. If no deflection is observed, a standard two-arm system is sufficient. If deflection occurs, add more arms until the lumber is fully supported.

3.  Calculate Weight Capacity per Arm:

Divide the total weight of 2,000 lbs by the number of arms required. If four arms are needed, each arm should have a capacity of 500 lbs.

4.  Calculate Upright Capacity:

If you are using three uprights, the total capacity required per upright is:

(4 arms×500 lbs)/3 uprights=666.67 lbs per upright(4 \text{ arms} \times 500 \text{ lbs}) / 3 \text{ uprights} = 666.67 \text{ lbs per upright}(4 arms×500 lbs)/3 uprights=666.67 lbs per upright

By following these steps, you can ensure that your cantilever rack system is designed to safely and efficiently support the weight of your stored products.

Pros and Cons of Cantilever Racking

Many factors should be considered when deciding if cantilever racks are the right warehouse storage solution for your storage space.

Advantages

• Flexibility: Cantilever shelf are highly adjustable, allowing you to customize the spacing between arms to accommodate various product sizes. This flexibility makes it easy to reconfigure the rack system as your storage needs change.
• Accessibility: With no front columns to obstruct access, cantilever racks provide easy loading and unloading of items. This design allows for quicker and more efficient handling of materials, reducing labor costs and improving productivity.
• Space Utilization: Cantilever racks maximize vertical space in your warehouse, allowing you to store long and bulky items that would otherwise take up valuable floor space. By utilizing the full height of your storage area, you can increase storage density and make the most of your available space.

Disadvantages

• Cost: Cantilever storage rack can be more expensive than traditional pallet racks due to their specialized design and components. The initial investment may be higher, but the benefits of increased storage capacity and efficiency often outweigh the costs in the long run.
• Installation Complexity: Proper installation of cantilever racks requires precise calculation and professional expertise. Incorrect installation can lead to instability and potential safety hazards. It is essential to follow manufacturer guidelines and seek professional assistance if needed.
• Maintenance: Regular maintenance is necessary to ensure the safety and stability of cantilever racks. Routine inspections should be conducted to check for any signs of damage or wear. Damaged components should be replaced promptly to prevent accidents and maintain the integrity of the system.

When comparing cantilever racking to other storage solutions, it is important to weigh these pros and cons based on your specific storage needs and budget.

Common Issues and Solutions

During installation and operation, several issues may arise with cantilever racking systems. Common problems include deflection (sagging) of products between arms, products rolling off, and incorrect loading. To address these issues:

• Deflection: Ensure the correct number of cantilever arms is used, spaced appropriately to support the load without sagging. Perform a deflection test to determine the required number of arms.
• Product Rolling: Use inclined arms or add a lip to the end of straight arms to prevent cylindrical items from rolling off. This is especially important for items such as pipes and tubes.
• Incorrect Loading: Distribute the load evenly and avoid tip loading by placing heavier items at the base. Ensure that the load is centered on the arms to maintain stability.

Regular maintenance and safety checks can prevent these issues, ensuring the longevity and reliability of your cantilever racking system. It is important to follow manufacturer guidelines for installation and maintenance to avoid potential hazards and ensure safe operation.

Steps for Safe Installation

1.  Inspect All Components: Before beginning the installation, inspect all cantilever rack arms, uprights, braces, and other components for any signs of damage. Do not proceed with the installation if any items appear damaged or if there are missing parts, especially for double-sided cantilever rack.

2.  Lay Out the Rack Footprint: Mark the layout of the rack footprint on the floor using chalk lines. This will help ensure proper alignment during installation.

3.  Connect the Cantilever Rack Base to the Column: Attach the base to the upright column using the supplied hardware, ensuring that the bolts are torqued to the manufacturer’s specifications.

4.  Anchor the Rack to the Floor: Install wedge anchors into the concrete floor according to the manufacturer’s instructions. Use shims as required to ensure stability.

5.  Connect the Arms: Attach the arms to the uprights using the supplied hardware. Ensure that the arms are securely fastened and properly aligned.

6.  Install Arm Accessories: If using arm lips or pipe stops, attach them to the front of the arms using the supplied hardware.

7.  Construct Additional Columns: Erect additional columns by following the same steps as the first column. Ensure that all components are securely fastened and properly aligned.

8.  Install Bracing: Connect the bracing to the back of the cantilever rack system using the supplied hardware. Tighten structural connectors to the snug-tight condition to ensure stability.

9.  Build Additional Adder Bays: Continue to erect and build adder bays to supplement your starter bays until the heavy duty cantilever rack systems and footprint are achieved.

By following these steps, you can ensure a safe and stable installation of your cantilever racking system, reducing the risk of accidents and damage to stored items.

If you have cost concerns, it's important to evaluate the state of used cantilever racks for sale and brand new heavy duty cantilever steel racking system before installation. A professional installation team is also highly recommended for safe operation.