Overestimating Capacity Needs
On the opposite side of the spectrum, you don’t want to have overkill on your rack system capacity because it could end up costing you thousands of dollars. How so? Vertical storage space is extremely valuable. Generally, higher-capacity beams have taller profiles, also known as the “beam face.” These taller profiles literally use up vertical real estate. In today’s warehouses, space is money. Using beams that are too heavy-duty for your needs is wasteful and prevents your operation from reaching its efficiency potential. Let’s look at the example below.
This warehouse is storing plastic bins on cross beams that most likely have a shelf capacity of over 6000# per pair. Needless to say, they will never use all of that capacity. The pallet rack beams are taking up an extreme amount of vertical shelf space. With a 5″ cross beam face and 13 shelf levels, almost 5′ of vertical spaceis being used up by the beams. If they had opted for lighter-duty 2.5″ beams, they would have had over 3′ of additional real estate they could use to store more inventory.