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How to Design Drive-In Racks: The Complete Guide
Classification:
FAQ
Release time:
2025-08-20
Designing a drive-in rack system is one of the most effective ways to maximize warehouse space and improve pallet density. Unlike conventional racking systems, drive-in racks allow forklifts to enter the storage lanes directly, making them ideal for high-density storage of homogeneous products. But how do you design drive-in racks that are safe, efficient, and tailored to your warehouse needs? Let’s break it down step by step.
What Are Drive-In Racks?
Drive-in racks are high-density pallet storage systems where pallets are stored on rails inside deep lanes. Forklifts drive into the lanes to deposit or retrieve pallets. This system follows the LIFO (Last In, First Out) principle, making it perfect for industries with non-perishable or low-SKU products such as:
- Food and beverage storage
- Cold storage warehouses
- Bulk commodity warehouses
Essential Components of Drive-In Racks
Drive-in racks require more accessories to ensure stability and safety due to high-density storage:
- Arm (Bracket): Connects upright to load-supporting rail (single or double-sided).
- Support Rail (Load Beam): Primary support for pallets.
- Top Beam & Top Bracing: Strengthens the upright frame connection.
- Back Bracing: Provides additional stability for single-entry racks.
- Column Guards: Protect uprights from forklift impact.
- Guide Rails: Assist forklifts when entering lanes.
Design Considerations for Drive-In Racking Systems
Single-Entry vs. Double-Entry Drive-In Racks
- Single-entry racks (against the wall): Depth should be limited to 6 pallets.
- Double-entry racks (accessible from both sides): Total depth should be within 12 pallets.
Limiting depth ensures forklift efficiency and safety since forklifts operate in continuous “high-lift” mode, which increases vibration and collision risks.
Height and Stability Requirements
Drive-in racks are less stable compared to selective racks, so the total height should not exceed 10 meters.
To enhance stability:
- Use larger upright sections.
- Add tie beams, top beams, and bracing systems.
- Recommended pallet load: ≤ 1500 kg.
- Pallet span should not exceed 1.5 meters.
- Compatible forklifts: Reach trucks or counterbalanced battery forklifts.
Upright Frame Selection
Depth of Upright Frame
Typically pallet depth + 30–50 mm.
If goods exceed pallet size, extra depth should be added.
For heavy-duty applications, increase the frame depth or add more frames.
Pallet positions are often designed in odd numbers (3/5/7).
For stability, the last bay is often designed as a beam-type rack.
Load Capacity & Height
Racks under 6.5 m and pallet weight ≤1000 kg → use 90 mm upright.
Racks over 6.5 m → use 100 mm upright.
For single-entry racks, pallet positions should not exceed 5 pallets deep.
Top Beam Selection
The clear entry (CE) dimension of the top beam = pallet (including goods) size +150 mm.
If pallets have overhanging goods, consider longer arms and larger CE.
Ensure forklift compatibility:
- Minimum 75 mm clearance between forklift body and uprights.
- Minimum 75 mm clearance between forklift overhead guard and load beam.
- Common specifications: 80×40×1.5 mm or 60×40×1.5 mm rectangular tube.
- Uprights of 90/100/120 mm typically use 80×40×1.5 mm beams.
Cantilever Arm (Bracket) Selection
Load Capacity
When a single pallet (including goods) weighs ≤1200 kg → use 60H cantilever arm (thickness 3.5 mm).
When 1200 kg < pallet weight ≤1500 kg → use 80H cantilever arm (thickness 3.5 mm).
When pallet weight >1500 kg, additional upright frames must be added in the depth direction to share the load capacity of the cantilever and uprights.
Connection Method Between Cantilever Arm and Upright
For pallet loads ≤1500 kg:
- 90H cantilever arms → hook connection.
- 120H cantilever arms → hook connection.
- For 100H cantilever arms → only bolt connection is allowed.
In low-temperature cold storage (–18°C to –30°C) or when pallet load ≥1500 kg, perforated cantilever arms with bolt connections are recommended for safety.
During planning, the exact cantilever position on the upright must be drawn precisely according to the upright and arm type.
Load Rail (Cantilever Beam) Selection
For ambient warehouses:
- Pallet load ≤1200 kg → beam thickness 1.8 mm.
- 1200 kg < pallet load <1500 kg → beam thickness 2.0 mm.
- Pallet load =1500 kg → beam thickness 2.3 mm.
For cold storage (–18°C to –30°C):
- Material must be Q235D steel for better low-temperature performance.
Top Cross Bracing Arrangement
Lateral (CE direction):
- Both sides must have top bracing.
- In the middle section, cross bracing should be arranged alternately, with one bracing for every pallet bay.
Longitudinal (Depth direction, D direction):
- Cross bracing should be installed between upright frames and between single uprights.
- No cross bracing between frame-to-frame ties.
Specification:
Cross bracing uses 45×24×1.5 mm rolled channel steel (for 90 uprights) or φ32×1.5 mm round tubes, arranged in an “X” pattern.
Overlapping centers are bolted together.
Back Cross Bracing Selection
Arrangement:
The number of back cross braces = the number of storage levels.
Example: for 3 storage levels, install 3 pairs of back braces (regardless of whether the level is supported by cantilever arms or beams).
Specification:
30×30×4 mm flat steel + M8 turnbuckles (“oo type”).
Key Advantages of Drive-In Racks
High Storage Density
Drive-in racks allow multiple pallets to be stored in depth, utilizing up to 80% of warehouse space compared to selective racks.
Cost-Effective Solution
Provides higher storage capacity without expanding warehouse buildings, reducing overall infrastructure costs.
Ideal for Cold Storage and Freezers
By minimizing aisles and maximizing density, drive-in racks help lower cooling energy costs in temperature-controlled warehouses.
Efficient Storage for Homogeneous Products
Perfect for industries with large volumes of the same SKU, such as food & beverage, chemicals, and bulk commodities.
Customizable Design
Rack depth, height, and load capacity can be tailored to match pallet size, forklift type, and warehouse layout.
Improved Inventory Management (LIFO System)
Works well for Last In, First Out storage, ensuring smooth handling of goods that don’t require strict FIFO rotation.
Compatible with Standard Forklifts
Designed for reach trucks and counterbalanced forklifts, ensuring easy operation and high reliability.
Common Mistakes to Avoid
- Designing lanes too deep, making retrieval inefficient.
- Ignoring pallet uniformity → instability.
- Overloading racks without proper calculation.
- Poor forklift clearance planning.
Conclusion
A well-designed drive-in racking system balances density, stability, and safety. From upright sizing to cantilever arm connection methods, every detail plays a role in ensuring long-term reliability. By following these design principles and using high-quality steel components, warehouses can significantly improve storage efficiency.
At HEGERLS, we provide customized drive-in racking solutions tailored to warehouse layouts, load requirements, and cold storage needs. Our engineering team ensures every rack is designed with precision, safety, and efficiency in mind.
Looking to optimize your warehouse with drive-in racks? Contact HEGERLS today for expert consultation and a customized storage solution.
FAQ
1. What is a drive-in racking system?
A drive-in racking system is a high-density storage solution where forklifts enter the rack structure to load and retrieve pallets, typically operating on a last-in, first-out (LIFO) basis.
2. When should a warehouse use drive-in racks?
Drive-in racks are ideal for warehouses storing large quantities of the same product with low SKU variety, especially when maximizing storage density is more important than fast item access.
3. What are the key factors to consider when designing drive-in racks?
Important factors include pallet size, load weight, forklift type, storage depth, aisle width, and warehouse height, all of which affect system performance and safety.
4. How deep should a drive-in racking system be?
The depth depends on operational needs and SKU turnover, but overly deep lanes can reduce accessibility and increase the risk of product damage, so a balanced design is essential.
5. What is the load capacity of drive-in racks?
Load capacity varies based on structural design and materials, but it must be carefully calculated to ensure each level and lane can safely support the intended pallet weight.
6. How do drive-in racks improve warehouse space utilization?
They reduce the number of aisles required by allowing forklifts to enter storage lanes, which significantly increases storage density compared to selective pallet racking systems.
7. What safety considerations are important in drive-in rack design?
Key safety considerations include rack alignment, guide rails for forklifts, impact protection, proper load distribution, and ensuring structural stability under repeated operations.
8. What type of forklifts are best for drive-in racking systems?
Drive-in racks typically require narrow, maneuverable forklifts that can operate within confined rack lanes while maintaining stability during loading and unloading.
9. What are the limitations of drive-in racking systems?
Drive-in racks offer limited selectivity, rely on LIFO inventory flow, and may have higher risks of rack damage if not properly operated or designed.
10. Can drive-in racks be combined with automated systems?
While traditionally used in manual operations, drive-in racks can be adapted with semi-automated solutions such as shuttle systems to improve efficiency and reduce forklift movement.
11. How to optimize drive-in rack layout for efficiency?
Optimizing layout involves balancing storage depth, access frequency, and workflow design to minimize travel time while maintaining high storage density.
12. How to choose between drive-in racks and other racking systems?
Drive-in racks are best for high-density storage with low SKU variety, while selective or automated systems are better for operations requiring quick access and high flexibility.
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