Drive-In Pallet Rack Forklift Training | Apex Video Training Series

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Drive-In Rack Forklift Operator Training Video - Apex CompaniesProper Forklift Training to Load & Unload Drive-In Pallet Rack

We’ve installed our share of drive-in pallet rack for busy distribution centers handling large volumes of inventory with limited SKUs.  It’s a great dense storage solution maximizing both warehouse space and pallet storage. Unlike standard selective pallet rack, however, drive-in rack requires the forklift to physically be driven into the rack to place and select pallets. This process demands a well-trained, skilled driver. Apex is here to help ensure your drivers meet that requirement.

Our forklift training video provides a solid overview and essential steps for training your forklift drivers to load and unload drive-in pallet rack. A few of the key points that the video identifies for training success are the following:

Before your driver gets into the fork truck… confirm these four steps. These steps are important warehouse safety measures for all your pallet rack systems:

Forklift Driver Training for Drive-In Rack - Apex CompaniesImportant Steps Before Loading the Drive-In Rack:

  • Ensure all operators are OSHA trained
  • Always use standardized, quality pallets
  • Check for broken or splintered pallet runners – don’t place damaged pallets in the lane
  • Check that the load weight is under the rated system capacity

Drive-in pallet rack is designed so that pallets are placed on heavy-duty rails that run the full depth of the system. The video above shows that the pallets must be placed squarely on the rails to ensure safe storage and retrieval. The following steps outline the proper loading procedures:

Drive-In Pallet Loading Procedures

  • Square the forklift with the opening of the drive-in lane
  • Lift the pallet 3” to 4” above the rails (raising the pallet too high could strike the load above)
  • Slowly drive to the last open pallet position and carefully lower the pallet onto the rails
  • Slowly back out of the system
  • Repeat the process to fill all remaining pallet locations

Important Cautions

Should the pallet be misaligned (not centered squarely on the rails), the driver MUST re-enter the rack and re-secure the pallet onto the forklift.

Once the driver has the pallet secured on the forklift, it can be centered within the lane and lowered back onto the rails.

It is NEVER acceptable to attempt to push or pull the pallet along the rails hoping that it will “fall into place.” Unfortunately, that is a common and dangerous pallet loading error. This action stresses the system and could cause the pallet to shift and fall through the rails resulting in product and component damage and worker injury.

Forklift Training - Drive-In Pallet Rack - Apex Companies

Drive-In Unloading Procedures

To unload the system, the driver reverses the steps followed in loading the drive-in rack:

  • Square the forklift with the opening of the drive-in lane
  • Lift the pallet 3” to 4” above the rails (raising the pallet too high could strike the load above)
  • Slowly drive to the last open pallet position and carefully lower the pallet onto the rails. Always load a Drive-In lane working from the FLOOR-Up starting with the last (or furthest) location. • Slowly back out of the system
  • Continue to load pallets – floor up/ and from BACK to FRONT until the lane is full

Note, the driver must carefully consider the turning radius of the forklift once in the aisle to prevent rack impact and damage. The optional cant leg frame design provides additional clearance for easier forklift maneuverability around the drive-in system.

If you have any questions regarding drive-in pallet rack systems design, operation or maintenance, call the Apex team. Our pallet rack experts are available to answer your questions or even evaluate the safety of your system and operations. We also offer on-site driver training, certification, and recertification for warehouse teams.