Apex Cracks Some Firsts in Subterranean Drive-In Rack Install | Project Spotlight
Drive-In Rack is the High-Volume Solution for Underground Cold Storage Warehouse
First, let us say that no eggs were harmed in the installation of this project, but no yolk, this is a unique one… and we’re just getting started. Take a look at Phase 1 of an underground selective and drive-in rack installation. Phase 2 is coming in early 2023. Here’s a quick recap of the project so far.
As old limestone mines go, this one makes a very cool warehouse storage resource. Nestled in the midwest region of the U.S., this underground storage facility leases over 3 million sq. ft. in total and is truck and rail. Our project focuses on a 90K sq. ft. warehouse space.
Take a look at the project specs.
Project Goals & Specs
- 90,000 sq. ft. cooler space
- Create 10,000 pallet positions
- Maximize storage capacity
- Optimize efficiency
- High-volume, low SKU count inventory
Working underground has some interesting challenges. For example, the building columns are 30’ x 30’ and irregularly shaped. The engineering & design team had to work around each column uniquely. In addition, there were hanging cooler units, evaporators, drain lines, and other overhead obstructions that we had to keep in mind.
Additionally, the customer is using odd-sized, plastic pallets which can bow under pressure if not supported underneath, and we were leaning towards drive-in rack to meet the capacity needs… let’s see how we worked out a successful solution.
Project Challenges
- 30’ x 30’ irregularly-shaped columns
- Plastic pallets 48”w x 36”d x 80”h –non-standard size
Apex Solutions:
- Drive-in racking designed around a 48” pallet WIDTH instead of depth, this design will allow for standard 48×40 pallets to be stored in future if needed.
- Drive-in rails were extended from 3” to 4” on each side to reduce potential “sagging” of plastic pallets.
Drive-in rack meets the customer’s need for high-volume storage of a small number of SKUs. It is a LIFO (Last-in/First-out) storage solution that coincides with their inventory management needs. To combat the concern about pallet sagging, we used wider drive-in rack arms to give the pallets more support. The system was also uniquely engineered to accommodate the wider pallets safely.
Also, the system configurations took on more of a free-form shape to work around the large columns while still managing to max out the space.
What Lies Beneath? Subterranean Installation
Once we contained the design within the space, it was time to bring it to life. This is definitely a project where expert pallet rack installation is critical…although we would say it’s always vital. Working within the underground space had unique anchoring and special considerations for securing the rack. For example, while we don’t typically recommend anchoring the rack to building walls… that is expressly prohibited in this case.
Our installation teams are skilled builders and certified equipment operators. We maintain a clean, safe workspace and get the job done on time and within budget. That’s why the Apex team is who to call when you have a rack project on the earth or below it.
The results are in for Phase 1 – our customer has been able to keep the drive-in racking nearly full at 95%, and the warehouse is in full operation. We’re gearing up for Phase 2 so stay tuned for more on this project, but if you’ve got some warehouse challenges of your own, give us a call. We’ve got the resources to help you meet your project goals.
Apex full-service support:
- Warehouse Design & Engineering
- Automation Solutions
- Project Management/Permitting & Installation
- Rack Inspections & Repair
- Material Handling Equipment
- Forklift Operator Training & Certification
- Forklift Service & Fleet Maintenance
- Equipment Financing, Leasing & Rentals
…with Apex, One Call Does It All.
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