Pallet rack systems are commonly used for warehouse storage, but the components are far more versatile than many people realize. In addition to storing palletized inventory, pallet rack parts can also be used to build extremely durable shop furniture such as workbenches, storage tables, and tool stations.
At Midwest Material Handling we often reuse pallet rack components around our own warehouse for practical shop projects. One of the most useful pieces we built was a heavy duty mobile workbench constructed entirely from used pallet rack components.
The goal was to create a strong work surface that could handle daily shop tasks while still being easy to move around the warehouse whenever needed.
Starting with a Used Pallet Rack Upright
The base of the workbench started with a used pallet rack upright frame that originally measured about 96 inches tall and 42 inches deep. Instead of using the full frame, we cut the upright in half to create two shorter frames that were the perfect height for a comfortable workbench.
Because pallet rack uprights are designed to support very heavy loads in warehouse environments, the finished bench provides excellent strength and stability even under demanding shop use.
Using pallet rack components also allowed us to build the structure using materials we already had available in our warehouse.
Adding Beams and Wire Decking
After preparing the upright frames, we installed 48″ pallet rack beams to create both the upper work surface and a lower storage shelf. Because pallet rack beams are designed for warehouse storage, the workbench ended up being extremely strong. The beam set used for this project is rated for approximately 6,000 pounds per shelf, far more capacity than typical shop workbenches or retail storage shelving.
Wire decking panels were installed across the beams to support each level. The lower shelf provides convenient storage for tools, materials, and small equipment while keeping the work surface clear.
Wire decks are commonly used in pallet rack systems because they distribute weight evenly across the beams while still allowing light and air to pass through the rack.
Creating the Work Surface
For the work surface we cut a sheet of plywood to fit over the wire decking on the top level of the rack. The plywood was secured to the decking using tek screws so it would remain firmly in place during everyday shop work.
Once installed, the plywood was coated with epoxy to improve the appearance and create a durable surface that holds up well to oils, grease, and general shop wear.
The result is a smooth, strong work surface that performs well for assembly work, small fabrication projects, and general shop tasks.
Making the Workbench Mobile
One of the most useful features of the bench is its mobility.
To allow the workbench to move easily around the shop, we welded four heavy duty casters (2 swivel with brakes and 2 rigid) directly to the pallet rack upright footplates. Two of the casters swivel and include locking brakes while the other two are rigid.
This configuration allows the bench to roll easily when needed and remain stable when locked into position.
Being able to reposition the bench anywhere in the warehouse has made it far more useful than a traditional stationary work table.
A Practical Use for Used Pallet Rack
This project is a good example of how pallet rack components can be repurposed for many different applications beyond warehouse storage.
Because pallet rack systems are modular and extremely strong, the components lend themselves well to custom shop projects such as workbenches, storage carts, tool tables, and garage shelving.
Another advantage of this design is flexibility. If the workbench is ever no longer needed, the entire structure can be disassembled in just a few minutes and the pallet rack parts can be reused for other storage projects.
No Project Is Too Small
Midwest Material Handling primarily supplies pallet rack systems and warehouse storage equipment to businesses throughout Ohio and across the country. At the same time, we always enjoy helping customers with smaller projects as well.
Whether someone needs a full warehouse storage system or just a few pallet rack components for a garage workshop or shop project, we are happy to help.
As we like to say, no project is ever too small.
