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Custom metal racks are used to store, move, and protect parts in factories, warehouses, and transport systems. They can hold automotive parts, machine parts, tools, panels, glass, and other products.
A rack should match the part and the work process. If the rack does not match the part, it may cause damage, use more space, or slow down production.
Before making a rack design, the buyer and the manufacturer need to collect information about the parts, handling method, storage area, and transport process. This article explains the main factors to consider.
Understand the Parts
The design process should start with the parts that the rack will hold.
The manufacturer needs to know:
- Part length
- Part width
- Part height
- Part weight
- Part shape
- Number of parts per rack
- Contact points
- Areas that need protection
Part drawings, photos, and samples can help the manufacturer understand the product.
The rack should support the parts at the right points. It should also stop the parts from moving or touching each other.
For example, a glass part may need rubber supports. A metal panel may need dividers. A machine part may need blocks that match its shape.
Calculate the Load Capacity
The rack must carry the weight of all parts placed inside it.
To calculate the load, multiply the weight of one part by the number of parts in the rack.
For example, if one part weighs 30 kilograms and the rack holds 20 parts, the total part weight is 600 kilograms.
The rack must support this weight during:
- Storage
- Loading
- Unloading
- Forklift handling
- Manual movement
- Truck transport
- Stacking
The rack weight should also be included when choosing wheels, forklift pockets, and lifting equipment.
If racks will be stacked, the rack at the bottom must carry the weight above it. A load test should be completed before production.
Choose the Rack Size
The rack size should match the part size and the number of parts required in each load.
The buyer should also check the space where the rack will be used.
Measure:
- Factory doors
- Warehouse aisles
- Elevators
- Production line areas
- Forklift routes
- Truck loading areas
- Shipping containers
A rack may hold the parts but still cause problems if it cannot pass through a door or fit inside a truck.
The rack size should also support the flow of parts. Workers should be able to move it without blocking other work areas.
Select the Handling Method
The rack structure depends on how workers or machines will move it.
Forklift Handling
If the rack will be moved by a forklift, it needs fork pockets or space under the base.
The manufacturer should know:
- Fork entry direction
- Fork width
- Fork length
- Forklift capacity
- Floor conditions
Some racks allow forklift entry from two sides. Others allow entry from four sides.
Manual Handling
If workers will push the rack, it may need wheels, handles, and brakes.
The wheel type should match:
- Rack weight
- Floor type
- Travel distance
- Turning space
- Use frequency
The handle height should allow workers to move the rack without bending or lifting.
Automated Handling
If the rack will work with a conveyor, robot, or automated guided vehicle, the rack base must match the equipment.
The rack dimensions, position points, and bottom structure should be checked before production.
Plan the Loading and Unloading Process
Workers should be able to place parts into the rack and remove them without extra steps.
The design should consider:
- Loading direction
- Unloading direction
- Worker access
- Part height
- Part weight
- Space between parts
- Use of lifting tools
Doors, bars, shelves, and dividers should not block access.
If the parts are loaded by a robot, the position of each part must match the robot path.
A sample rack can be used to test the loading process.
Add Part Protection
The rack should protect parts during storage and movement.
Protection materials may include:
- Rubber pads
- Plastic blocks
- Foam
- Fabric
- Dividers
- Straps
- Locking bars
- Covers
The material should be placed at the contact points between the rack and the part.
It should not leave marks, scratch the surface, or change the part shape.
Protection parts should also be replaceable. If a rubber pad or plastic block wears out, workers should be able to replace it without changing the rack frame.
Decide Between Stackable and Foldable Designs
A stackable rack can reduce floor use. A foldable rack can reduce space during return transport.
Stackable Racks
The rack needs stacking feet or corner posts that connect with the rack below.
The design should confirm:
- Number of racks per stack
- Load in each rack
- Warehouse height
- Forklift lifting height
- Stack position
The racks should not slide or tilt during storage.
Foldable Racks
Foldable racks are used when empty racks need to return to the supplier.
The folding system should be easy for workers to use. It should also include locks to hold the rack open during use.
The buyer should check how much space the rack uses before and after folding.
Choose the Material
Steel is often used for metal rack frames. The steel size and thickness depend on the rack load and structure.
The manufacturer should select the material based on:
- Part weight
- Rack size
- Stacking load
- Handling method
- Use environment
- Use cycle
Using more steel than needed can increase the rack weight and cost. Using less steel can affect the load capacity.
The design should balance the rack weight and the required load.
Select the Surface Treatment
Metal racks need surface treatment to reduce rust and wear.
Common choices include:
- Powder coating
- Paint
- Galvanizing
The choice depends on where the rack will be used.
Indoor racks may use powder coating or paint. Racks used outside, near water, or in areas with chemicals may need another treatment.
The buyer should explain the work environment to the manufacturer.
Consider Storage and Transport Space
The rack should use warehouse and truck space in a planned way.
Check how many racks can fit in:
- One warehouse row
- One truck
- One shipping container
- One production area
Rack dimensions can affect transport cost. A small change in height or width may allow more racks to fit in one truck.
The rack should also match the return transport plan. Stackable or foldable designs may reduce the number of return trips.
Include Safety Features
The design should reduce the risk of parts falling or racks moving.
Safety features may include:
- Wheel brakes
- Locking bars
- Doors
- Straps
- Stack guides
- Forklift stops
- Part stops
Workers should receive instructions about load limits, stacking limits, and handling methods.
The rack should be checked during use. Damaged wheels, welds, supports, and locks should be repaired or replaced.
Test a Sample Before Production
A sample rack should be made before the full order begins.
The sample test should include:
- Loading parts
- Unloading parts
- Moving the rack
- Forklift handling
- Wheel testing
- Brake testing
- Stacking
- Truck loading
- Part protection
Workers who will use the rack should take part in the test. They may find problems that are not shown in drawings.
Changes should be made before production starts.
Conclusion
Designing a custom metal rack requires information about the parts, load, space, handling equipment, and work process.
The rack should hold the parts, protect them, fit the factory, and support transport. The design should also consider stacking, folding, wheels, forklift pockets, surface treatment, and safety.
Send part drawings, photos, samples, and process information to the manufacturer. Test a sample rack before placing the full order. These steps can help the rack match the parts and the way they move through the factory.