Can You Mix Manufacturer Components for Pallet Rack System Expansion?

Expert Advice on Mixing & Matching Pallet Rack System Components

Adapting to the rapid changes of the last few years has been top-of-mind for many warehouse operators. Among the challenges is storage capacity to meet demand growth and an increase in buffer stock. As a result, many have considered expanding their existing pallet rack system. This is a great solution that can take advantage of vertical space and free up floor space for other activities. It’s a win-win in many cases but can lead to a major failure if not executed safely. 

In the search for a quick and cost-effective fix, it’s tempting to go with a mix and match approach using components from different pallet rack manufacturers. Can this be done? The short answer is YES – but there are a few caveats to consider before jumping in – it’s critical that you have a proper engineering review, including stamped drawings and calculations. Working with the right design team who has proven resources and experience to take all the necessary precautions is the best way to ensure the safety and function of your new pallet rack system.

Let’s look at what’s at stake and ways to ensure you get the capacity you need without jeopardizing warehouse safety.

Pallet Rack Mix & Match Cautions

• System failure due to incompatible parts
• Voided manufacturer warranty 
• Invalid component capacities
• Incompatible connections
• Variance in length tolerance
• Permitting & insurance difficulties

 

System failure – Clearly, the biggest concern with mixing pallet rack components from different manufacturers is the potential for component failure. At the risk of sounding overly alarmist, the Rack Manufacturer’s Institute (RMI) notes that system collapse often results from mixing incompatible components from different rack manufacturers. So, let’s take that as a lesson learned and ensure compatibility as the first step.

Voided warranty—Using new components will void your warranty if you don’t follow the manufacturer’s policy prohibiting mixing products. Looks can be deceiving. Product differences start at the core with variations in steel gauge and continue through the production process, including bracing styles, trusses, beam connectors, and locking devices.

Invalid component capacities – The manufacturer bases pallet rack load capacities on system design, not individual components. The engineering design and stamped approval are key here to ensure the safety of your rack expansion. The pallet rack system design incorporates the rack components with the facility conditions, i.e., seismic and temperature, plus the load specs and equipment to ensure the system is safe for the intended use.

Incompatible connections – This is one area where “good” is NOT good enough. Due to inconsistencies in manufacturing beam connectors, column extensions, bracing, and safety pins, a variety of components may be left unsecured. A professional rack design and installation team will make all the right connections to secure the structural integrity of the pallet rack system.

Variance in length tolerance—Standard beam lengths are not as standard as you think. Slight variations exist between rack manufacturers, which can cause the beam to not be seated properly and require a different locking device. This is a great question to ask your rack design and installation team. Make sure they are equipped to answer all of your questions about proper fit and construction and can back up all that talk with approved engineering documents.

Permit and insurance challenges—Usually, the goal is to avoid extra headaches, but by conflicting with engineering and/or building codes, you’re likely to open yourself up to a more complicated permitting and insurance approval processes. Don’t reach for the Advil; instead, call Apex.

 

All the Right Connections for Pallet Rack System Expansion

 

Making the right connections starts with a trusted systems design and engineering team that understands the integration challenges of mixing new or used manufacturer components. Apex is a full-service provider that is with you from the start of the project right through to sign-offs. We have warehouse design experts, professional rack installers, and rack repair specialists should the need arise down the road. Our team is cross-trained to deliver the solution that meets your operational and ROI goals on time and within budget. 

Call Apex today to discuss your warehousing challenges and timelines –we promise to be the best connection you make.