Every so often, we have the opportunity to revisit a project we completed years ago. It’s always interesting to see how the equipment has held up over time.
Recently, we stopped by one of our long-time customers to take another look at a Copperloy-JH Industries dock-to-ground ramp that Midwest Material Handling installed approximately 20 years ago. While the yellow paint has faded from years of Ohio weather, the ramp itself remains structurally sound and continues to provide safe, dependable forklift access every day.
Projects like this are a reminder that quality equipment, combined with a thoughtful installation, can provide decades of reliable service.
A Unique Installation
This wasn’t a typical installation. The building originally had an older Rite-Hite mechanical dock leveler that had deteriorated beyond practical use. Rather than removing the entire dock leveler and rebuilding the dock opening, we installed the Copperloy dock-to-ground ramp directly over the existing structure.
The result was a permanent transition from ground level to the loading dock without the expense and disruption of major demolition. More than two decades later, that solution continues to perform exactly as intended.
Built for Everyday Forklift Traffic
This dock-to-ground ramp is approximately 30 feet long with a 20,000-pound capacity, making it well suited for most forklifts used in warehouse and industrial applications.
While this installation is a permanent dock-to-ground ramp, many businesses choose portable yard ramps when flexibility or temporary loading access is needed. Midwest Material Handling supplies both permanent and portable yard ramps throughout Ohio, helping customers find the right solution for their facility.
Simple Design. Proven Performance.
Sometimes the simplest design features make the biggest difference.
One of the most noticeable features of this Copperloy ramp is the serrated open steel grating. Unlike solid steel decking, the open grating allows rain, snow and debris to pass through instead of collecting on the surface. The serrated edges also provide excellent traction for forklifts in wet or snowy conditions.
The heavy steel side curbs help guide forklifts safely up and down the ramp while adding strength to the overall structure. Looking at the ramp today, it’s easy to see that these design features have contributed to its longevity.
Looking Beyond the Paint
After spending more than 20 years outdoors, it’s perfectly normal to see faded paint and a little surface rust. What impressed us wasn’t the cosmetics. The heavy steel frame remains straight and solid. The side curbs show very little impact damage, and the serrated grating continues to provide a secure driving surface for daily forklift traffic.
It’s easy to focus on appearance, but structural integrity is what really matters. This ramp continues to do the job it was built to do.
Approximate Specifications
Manufacturer: Copperloy
Manufactured in Ohio
Approximate Length: 30 feet
Capacity: 20,000 pounds
Heavy structural steel construction
Serrated open steel grating for excellent traction and drainage
Heavy steel side curbs
Permanent dock-to-ground installation
We Sell and Rent Yard Ramps
Not every operation requires a permanent installation. In addition to selling new and used yard ramps, Midwest Material Handling also offers yard ramp rentals throughout Ohio. Renting is an excellent option for seasonal demand, temporary warehouse expansions, equipment breakdowns or short-term projects where purchasing a ramp doesn’t make sense.
Whether you need a portable yard ramp for a few weeks or a permanent dock-to-ground ramp for decades of service, we’re happy to help you choose the right solution.
Need a Yard Ramp for Your Facility?
Whether you’re looking for a permanent dock-to-ground ramp, a portable yard ramp or a short-term rental, Midwest Material Handling can help. We sell new and used yard ramps, offer rental options throughout Ohio and can recommend the best solution based on your loading dock, forklift capacity and application.
Need a quote or have questions? Contact Midwest Material Handling today. We’ll help you find the right ramp for your operation. In addition to yard ramps, Midwest Material Handling supplies a full line of material handling equipment for warehouses and distribution centers throughout Ohio.
Frequently Asked Questions
How long do yard ramps typically last?
A quality steel yard ramp can provide decades of reliable service when properly maintained. The Copperloy ramp featured in this article has been in service for more than 20 years and remains structurally sound and is used regularly.
What is the difference between a dock-to-ground ramp and a portable yard ramp?
A dock-to-ground ramp is a permanent installation that provides forklift access between ground level and a loading dock. A portable yard ramp can be moved to different loading locations, making it ideal for facilities without a permanent dock or businesses that need flexibility.
Do you rent yard ramps?
Yes. Midwest Material Handling rents yard ramps throughout Ohio for temporary projects, seasonal demand, warehouse expansions and emergency loading situations.
What yard ramp capacity do I need?
That depends on the combined weight of your forklift and its load. We can help determine the appropriate ramp capacity based on your equipment and application.
Do you install dock-to-ground ramps?
Yes. We provide installation services for permanent dock-to-ground ramps as well as sales, rentals and service throughout Ohio.
Loading dock bumpers are one of the most important components of any loading dock system, yet they are often overlooked until damage occurs. The right loading dock bumper protects your building, dock equipment, dock seals, and loading dock infrastructure from costly trailer impacts that occur during daily loading operations.
Many facility managers assume all dock bumpers are the same. In reality, selecting the proper loading dock bumper requires evaluating trailer traffic, loading dock conditions, trailer movement, dock equipment, and the amount of protection required. A bumper that works well for a small warehouse may be completely inadequate for a busy distribution center operating multiple shifts and handling dozens of trailers each day.
This dock bumper selection guide explains how to choose the proper loading dock bumper for your application and avoid common mistakes that can lead to expensive repairs, excessive maintenance, and premature equipment failure.
Why Loading Dock Bumpers Matter
Every time a trailer backs into a loading dock, impact forces are transferred to the building. Without proper protection, these repeated impacts can damage concrete dock walls, dock levelers, dock seals, trailer restraints, and other loading dock equipment.
Contrary to popular belief, dock bumpers are not designed to stop a trailer. Their primary purpose is to absorb impact and maintain the proper stand off distance between the trailer and the building. This cushioning effect helps protect the loading dock while reducing wear on equipment and building structures.
Even low-speed trailer impacts create substantial force. Over time, repeated contact can lead to cracked concrete, damaged dock equipment, torn dock seals, and costly repairs that far exceed the cost of properly selected dock bumpers.
Step 1: Evaluate Your Loading Dock Traffic
The first step in selecting a loading dock bumper is understanding how frequently trailers use the dock. Traffic volume has a direct impact on bumper wear and the level of protection required.
A small warehouse receiving a few deliveries per day has very different needs than a high-volume distribution center operating around the clock. Facilities with light traffic may perform well with molded dock bumpers or standard laminated dock bumpers. Manufacturing facilities, regional warehouses, and food processing plants generally benefit from laminated dock bumpers due to their superior durability and impact absorption.
At the high end of the spectrum are distribution centers, e-commerce fulfillment facilities, and cross-dock operations. These facilities often experience constant trailer movement and typically require more robust protection, including steel face dock bumpers and other heavy-duty impact protection systems. As a general rule, the more trailer traffic a facility experiences, the more durable the dock bumper system should be.
Step 2: Understand the Difference Between Laminated and Molded Dock Bumpers
Most loading dock bumpers fall into one of two categories: laminated dock bumpers and molded dock bumpers.
Laminated dock bumpers are manufactured from layers of recycled truck and bus tire rubber compressed on heavy-duty steel rods. This construction creates a highly durable bumper capable of absorbing repeated impacts over many years of service. Because of their strength and longevity, laminated dock bumpers are the most common choice for warehouses, manufacturing facilities, and distribution centers.
Molded dock bumpers are manufactured from fiber-reinforced rubber compounds molded into a single solid piece. They are commonly used in lighter-duty applications and are often selected as replacement bumpers for dock levelers. While molded dock bumpers provide effective protection in lower-traffic environments, they generally do not offer the same level of durability as laminated bumpers in demanding industrial applications.
For most industrial facilities, laminated dock bumpers are considered the preferred choice due to their proven performance and long service life.
Step 3: Determine the Proper Dock Bumper Projection
Dock bumper projection refers to how far the bumper extends from the dock face. It is one of the most important factors to consider when selecting a dock bumper.
For most loading docks with level approaches, a 4-inch projection is considered the industry standard. This size provides adequate stand off distance for most trailers while protecting dock equipment and building structures from impact.
However, not every loading dock can use a standard 4-inch bumper. Facilities with dock seals, canopies, recessed dock positions, or unusual trailer conditions may require additional projection. If a bumper does not extend far enough from the dock face, trailers may contact dock seals, shelters, dock levelers, or even portions of the building itself.
Selecting the proper projection is critical because an undersized bumper often creates more problems than it solves.
Step 4: Evaluate Dock Approach Conditions
The approach leading to a loading dock has a significant impact on bumper selection.
A dock with a level approach generally allows standard dock bumpers to perform as intended. However, facilities with declined approaches often require additional protection because trailers back downhill toward the building. As the grade increases, the trailer moves closer to the dock face, increasing the likelihood of impact damage.
In these situations, extra thick dock bumpers or increased projection may be required to maintain the proper stand off distance. Facilities with steep declines frequently need specialized bumper configurations to prevent damage to dock equipment and building structures.
Although inclined approaches typically create fewer issues, they should still be evaluated when selecting dock bumpers. Understanding how trailers actually position themselves at the dock is one of the best ways to determine whether additional protection is needed.
Step 5: Consider Trailer Movement During Loading
Many facility managers focus on trailer impact when a truck backs into the dock. In reality, some of the most damaging wear occurs after the trailer is already parked.
Forklifts entering and exiting trailers cause trailers to move up and down throughout the loading process. Air ride suspension systems can also contribute to vertical movement as trailer weights change during loading and unloading.
This movement creates friction between the trailer and the dock bumper. Over time, constant rubbing can wear away bumper material and shorten service life. If dock bumpers are wearing out faster than expected, trailer movement is often a contributing factor that should be investigated.
Step 6: When Should You Use Steel Face Dock Bumpers?
Steel face dock bumpers are designed specifically for applications where excessive friction occurs due to trailer movement. These bumpers feature a heavy-duty steel plate mounted to the face of a laminated dock bumper. The steel plate protects the rubber from abrasion while still allowing the bumper to absorb impact energy.
Steel face dock bumpers are commonly found in distribution centers, cross-dock facilities, high-volume warehouses, and operations utilizing air ride trailers. They are also frequently recommended for facilities that use yard jockeys to move trailers throughout the day.
If standard laminated dock bumpers are wearing out prematurely, upgrading to steel face dock bumpers may dramatically extend service life and reduce replacement costs.
Step 7: Understand the Impact of Yard Jockey Operations
Facilities utilizing yard jockeys or shunt trucks often experience more severe dock bumper wear than facilities relying exclusively on over-the-road drivers.
Yard jockeys move trailers repeatedly throughout the day and often back trailers into position more aggressively. This creates additional impact forces and increases friction between the trailer and the dock bumper.
As a result, many large distribution centers use steel face dock bumpers, heavy-duty laminated bumpers, or increased bumper projection to better withstand these demanding operating conditions. When evaluating a dock bumper application, understanding who is moving the trailers can be just as important as understanding how many trailers visit the dock each day.
Step 8: Consider Trailer Impact Height
Not all trailers contact the dock at the same height. Trailer suspension, trailer design, refrigerated trailers, container chassis, and loading conditions can all affect impact points.
Facilities serving a wide variety of trailers may require additional vertical protection to prevent damage above or below the primary impact zone. This is one reason extra length dock bumpers are commonly used at facilities with dock seals or varying trailer heights.
When trailer impact points vary significantly, vertical dock bumpers or extended-height bumpers may provide better protection than standard bumper configurations. Evaluating trailer impact height is often overlooked, but it can play a major role in selecting the proper dock bumper system.
Step 9: Consider the Rest of the Loading Dock System
Dock bumpers should never be selected independently of the rest of the loading dock system. Everything works together.
Equipment such as dock levelers, dock seals, dock shelters, trailer restraints, and dock lifts can all influence bumper placement and projection requirements. Installing new equipment without considering bumper protection can create unexpected clearance issues and increase the risk of damage. We furnish a wide range of replacement dock leveler and vehicle restraint parts at true wholesale pricing.
For this reason, bumper selection should always be evaluated alongside the rest of the loading dock design.
Common Dock Bumper Selection Mistakes
Many loading dock problems can be traced back to improper bumper selection. One of the most common mistakes is choosing a dock bumper based solely on price. While inexpensive bumpers may reduce upfront costs, they often wear out faster and provide less protection in demanding applications.
Another frequent mistake is overlooking trailer movement. Facilities with air ride trailers, forklifts, or yard jockey operations often require more robust bumper protection than initially expected. Approach conditions are also commonly ignored. A dock with a declined approach may require significantly more bumper projection than a facility with a level approach.
Finally, many facilities wait too long to replace worn dock bumpers. By the time structural damage becomes visible, repair costs often exceed the cost of replacing the bumpers months earlier.
Signs Your Dock Bumpers Need Replacement
Dock bumpers should be inspected periodically as part of a routine maintenance program. Common signs that replacement may be needed include cracked rubber, excessive compression, exposed steel rods, bent mounting hardware, and visible damage to surrounding dock structures. Missing rubber sections and severe wear are also indicators that the bumper is no longer providing adequate protection.
Replacing dock bumpers before complete failure can help prevent costly damage to dock equipment and building structures.
Frequently Asked Questions
What is the most common loading dock bumper size?
The most common dock bumper projection is 4 inches. This size provides adequate protection for most loading docks with level approaches.
Are laminated dock bumpers better than molded dock bumpers?
For most industrial applications, laminated dock bumpers provide greater durability and impact absorption than molded dock bumpers.
When should steel face dock bumpers be used?
Steel face dock bumpers are recommended when excessive friction occurs due to trailer movement, air ride trailers, yard jockey operations, or high trailer traffic.
How long do dock bumpers last?
Service life varies depending on traffic volume, operating conditions, and bumper style. High-quality laminated dock bumpers can provide many years of reliable service.
Are dock bumpers mounted to the building or trailer?
Dock bumpers are permanently mounted to the building structure and are designed to protect the loading dock from trailer impact.
Final Thoughts
Selecting the right loading dock bumper involves much more than choosing a standard size and bolting it to the wall. Traffic volume, trailer movement, dock approach conditions, impact height, and existing dock equipment all influence the proper solution.
By understanding how your loading dock operates and evaluating these factors carefully, you can select a dock bumper system that reduces maintenance costs, improves safety, protects valuable equipment, and extends the life of your loading dock investment.
If you need assistance selecting laminated dock bumpers, molded dock bumpers, steel face dock bumpers, extra thick dock bumpers, wheel chocks, or other loading dock equipment, Midwest Material Handling can help evaluate your application and recommend the best solution for your facility.
Perforated Steel Rack Decks: A Specialty Alternative to Standard Wire Decking
For most warehouse storage applications, standard wire decking remains the preferred solution for pallet rack systems. However, there are situations where a more specialized form of steel rack decking is needed. Standard wire decking is economical, durable, easy to install, and allows water from overhead fire sprinkler systems to penetrate through multiple rack levels.
In fact, standard wire mesh decking solves the storage needs of probably 95 percent of pallet rack users.
Occasionally, however, we receive a call from a customer who simply cannot use the traditional 2-inch by 4-inch wire mesh configuration found on a standard wire deck panel. Their products are too small, require a flatter storage surface, or need more continuous support than wire mesh can provide.
When that happens, perforated steel rack decking may be the perfect solution. This specialized form of steel pallet rack decking provides greater product support than traditional wire decking while still allowing sprinkler penetration.
Why Some Warehouses Need More Than Standard Wire Decking
Standard wire decking works exceptionally well for palletized loads, cartons, and general warehouse storage. It has become the industry standard because it is affordable, durable, and compatible with virtually every type of pallet rack system. However, not every storage application is the same.
Some warehouse products are small enough to settle into the openings of a wire deck. Other products require a smoother storage surface for stability, product protection, or handling purposes. At first glance, a solid steel shelf seems like the obvious answer.
The problem is that most warehouse fire protection systems rely on water from overhead sprinklers reaching lower rack levels. Completely solid shelving can interfere with sprinkler penetration and create concerns with fire protection requirements. This is where perforated steel rack decking fills an important niche.
What Is Steel Rack Decking?
Steel rack decking is a broad category of rack shelving products designed to provide support for stored materials within a pallet rack system. One specialty form of steel rack decking is perforated steel decking, which provides many of the benefits of a solid shelf while still allowing water, air, and light to pass through strategically placed perforations.
Steel rack decking is a broad category that includes wire decking, perforated steel rack decking, corrugated decking, and solid steel pallet decking systems designed for pallet rack storage.
The result is a storage surface that is significantly more continuous than traditional wire decking while maintaining the open area needed for sprinkler effectiveness.
For customers who cannot work with a traditional 2-inch by 4-inch wire mesh pattern, perforated steel decking often provides the best of both worlds.
A Specialized Product for a Specialized Application
Perforated rack decking is not a high-volume warehouse product.
In fact, only a handful of manufacturers in North America currently produce these specialized deck panels.
One of the industry’s leading manufacturers is Nashville Wire Products, widely recognized as one of the largest wire decking manufacturers in the United States.
These decks are specifically designed for warehouse operators who need something between traditional wire mesh decking and solid steel rack shelving.
Unlike standard pallet rack steel decking, perforated decks are typically selected only when a warehouse requires a more continuous storage surface for cartons, small parts, or irregularly shaped products.
Because of the specialized nature of the product, perforated steel decks are typically specified only when standard wire decking, corrugated steel decking, or other shelf options are not suitable.
While perforated steel rack decks represent a very small percentage of the rack decking we sell, they are often the perfect solution when traditional wire decking, corrugated decking, or solid shelving cannot meet a customer’s storage requirements.
Nashville Wire Perforated Deck Specifications
Nashville Wire’s perforated steel rack decks are engineered similarly to traditional wire deck panels.
A standard 42-inch by 46-inch deck includes:
• Three structural support channels
• 18-gauge pre-galvanized steel construction
• Compatibility with standard pallet rack systems
• Designed for 1 5/8-inch step beams
• 1-3/4-inch top of beam dimension
These specialized deck panels are designed to fit standard pallet rack systems utilizing A-style and 5/8-inch step beams commonly found in warehouses throughout Ohio and across the country.
The use of pre-galvanized steel provides additional corrosion resistance and long-term durability, making these decks suitable for demanding warehouse environments.
How Much Weight Can a Perforated Steel Deck Hold?
The Nashville Wire perforated steel deck carries a uniform distributed load capacity of approximately 2,000 pounds per panel.
For many warehouse applications, this capacity is more than adequate.
Other manufacturers, including Little Giant, offer solid steel and perforated steel rack decks with capacities of approximately 3,000 pounds per panel.
While the additional capacity may be beneficial in certain situations, many customers simply do not require that level of loading.
The Nashville Wire design often strikes an excellent balance between strength and cost.
How Much More Do Perforated Steel Rack Decks Cost?
Let’s be honest. Nobody purchases perforated steel rack decks because they are the least expensive option. They are a specialty product designed to solve a specific storage problem.
As a general comparison:
• Standard wire decking serves as the baseline
• Nashville Wire perforated steel decks typically cost about five times (5X) more than a standard wire deck panel
• Solid steel and heavy-duty perforated steel decks from other manufacturers often cost approximately seven times (7X) more than standard wire decking
That means the Nashville Wire perforated deck can be roughly 30 percent less expensive than competing solid steel or perforated steel deck designs.
For customers who need this type of storage surface and dont need the higher capacity, that cost difference can be significant.
What About Corrugated Steel Rack Decking?
Corrugated steel decking is another option frequently considered when a more solid storage surface is needed. It is generally less expensive than perforated steel rack decking and provides more product support than traditional wire mesh.
Some warehouse managers evaluating solid steel pallet decking also consider corrugated steel decking because it provides a more continuous surface than wire mesh. However, corrugated panels still contain ridges and valleys that may not be suitable for every application.
For some products, those grooves create the very problem the customer is trying to eliminate. When a flatter, more uniform storage surface is required, perforated steel rack decks often become the preferred solution.
Steel Pallet Rack Decking Options
Warehouse operators today have several steel pallet rack decking options available. Traditional wire decking remains the most common solution, while corrugated decking, solid steel pallet decking, and perforated steel rack decking are generally reserved for more specialized storage applications.
Perforated Steel Rack Decks vs. Wire Decking
Feature
Standard Wire Decking
Perforated Steel Rack Decking
Cost
Lowest Cost Option
Approximately 5x Higher
Sprinkler Penetration
Excellent
Excellent
Surface Continuity
2-inch x 4-inch Mesh Openings
Nearly Continuous Surface
Capacity
Varies by Deck
Approximately 2,000 lbs. UDL
Corrosion Resistance
Excellent
Excellent
Best Application
General Warehouse Storage
Small Parts & Specialty Storage
For the vast majority of warehouse operations, wire decking remains the best value. Perforated steel decks are reserved for applications where a more continuous storage surface is required.
Advantages of Perforated Steel Rack Decking
Perforated steel decks offer several unique benefits:
✔ More continuous storage surface than wire decking
✔ Better support for small products and irregular items
✔ Allows water from sprinkler systems to penetrate lower rack levels
✔ Durable galvanized steel construction
✔ Cleaner appearance than corrugated decking
✔ Compatible with standard pallet rack beams
✔ Available in multiple capacities and configurations
For the right application, these advantages can easily justify the additional investment.
Not the Right Choice for Every Warehouse
The vast majority of pallet rack systems will continue to use traditional wire mesh decking because it provides the best combination of performance, safety, and affordability.
However, every warehouse has unique storage requirements. When product size, storage conditions, or operational needs make standard wire decking unsuitable, perforated steel rack decks provide a highly effective alternative.
They are not designed for every warehouse. They are designed for the warehouse manager who has a very specific challenge and needs a very specific solution.
And when that challenge exists, few products perform better.
Need Help Selecting the Right Rack Decking?
Choosing the right decking solution is about more than load capacity. Product size, fire protection requirements, storage methods, and budget all play a role in determining the best option for your warehouse.
Midwest Material Handling supplies steel rack decking solutions throughout Ohio, including standard wire decking, perforated steel rack decking, steel pallet rack decking, and other specialty rack shelving products. Whether you’re installing a complete pallet rack system or upgrading an existing storage area, we can help identify the right solution for your warehouse storage application.
Contact Midwest Material Handling today to discuss your storage requirements and request pricing on perforated steel rack decks, wire decking, or complete pallet rack systems.
Frequently Asked Questions About Perforated Steel Rack Decking
What is perforated steel rack decking?
Perforated steel rack decking is a specialty pallet rack shelf designed with thousands of small openings that allow water, air, and light to pass through while providing a more continuous storage surface than traditional wire decking.
Is perforated steel rack decking stronger than wire decking?
Not necessarily. Load capacity depends on the design, gauge of steel, deck dimensions, and support structure. The Nashville Wire perforated deck discussed in this article carries a uniform distributed load capacity of approximately 2,000 pounds per panel.
Does perforated steel rack decking meet fire code requirements?
Perforated steel rack decking is designed to allow water from overhead sprinkler systems to penetrate through rack levels more effectively than solid steel shelving. However, fire code requirements vary by facility and should always be reviewed with a qualified fire protection professional.
How much does perforated steel rack decking cost?
Perforated steel rack decking typically costs approximately five times more than standard wire decking. Some heavy-duty perforated and solid steel deck systems can cost as much as seven times more than traditional wire mesh decking.
What sizes are available?
Perforated steel rack decks are available in multiple widths and depths to fit common pallet rack configurations. Popular sizes include 42-inch and 48-inch depths with widths designed for standard pallet rack beam lengths.
What is the difference between perforated decking and corrugated steel decking?
Corrugated steel decking uses raised ribs and valleys to increase strength, while perforated decking provides a flatter and more uniform storage surface. Warehouses storing small cartons, parts, or products that require continuous support often prefer perforated decking.
Can perforated steel rack decks be installed on existing pallet rack systems?
Yes. Most perforated steel rack decks are designed to fit standard pallet rack beams. The Nashville Wire design referenced in this article is compatible with 1 5/8-inch step beams.
What is the difference between steel rack decking and wire decking?
Steel rack decking is a broad category that includes wire decking, perforated steel rack decking, corrugated decking, and solid steel pallet decking. Wire decking remains the most common choice for general warehouse storage, while specialty forms of pallet rack steel decking are typically used when additional product support or a more continuous storage surface is required.
When should I choose perforated steel rack decking instead of wire decking?
Perforated steel rack decking is typically chosen when products are too small for traditional wire mesh openings, require a flatter storage surface, or need greater product support. For most palletized storage applications, standard wire decking remains the more economical and practical solution.
Who Says Pallet Rack Is Just for Pallets? A Vinyl Record Storage Story
When most people think of pallet rack, they picture forklifts moving palletized inventory throughout a warehouse. That’s certainly the most common application, but it’s far from the only one.
Over the years, we’ve seen pallet rack used to store everything from machine parts and archived documents to retail inventory and collectibles. A recent project for a long-established Cincinnati-area company in Loveland reminded us just how versatile standard teardrop pallet rack can be.
This customer specializes in buying, selling, and distributing vinyl records, including LPs, 45s, and 78s. As their inventory continued to grow, they needed a storage system that would keep thousands of records organized while making the most of their available warehouse space. Rather than investing in a custom storage system, they turned to standard Husky Rack & Wire teardrop pallet rack components.
The result is one of the most efficient uses of vertical storage space we’ve seen in years.
Notice the Lack of Wasted Space
Take a close look at the photo. One of the first things you’ll notice is the minimal amount of space between the top of the cartons and the beam level above them.
Many warehouses waste a surprising amount of vertical storage capacity because beam levels are spaced too far apart. Every inch of unused air between storage levels represents storage capacity that isn’t being utilized.
This installation is the exact opposite.
The beam elevations were carefully configured to closely match the height of the record cartons being stored. As a result, there is virtually no wasted space between storage levels. The customer has done an outstanding job of maximizing the full cube of the building rather than simply filling floor space.
Floor space is expensive, and building additions can be even more costly. Utilizing the vertical space you already own is often the most cost-effective way to increase storage capacity, making this project a textbook example of that philosophy.
Standard Teardrop Pallet Rack, Creative Application
One of the things that makes this project so interesting is its simplicity. The entire storage system was built using standard pallet rack components that we regularly stock for customers throughout Cincinnati and Southwest Ohio.
The installation includes:
10-foot-high Husky Rack & Wire uprights
8-foot teardrop beams
Wire decking
42-inch deep upright frames
24-inch deep upright frames
A combination of new and used pallet rack components
No custom fabrication was required. Instead, the customer used readily available pallet rack components to create a highly organized storage system tailored specifically to their inventory.
While pallet rack is traditionally designed for palletized loads, it can also serve as an excellent heavy-duty shelving system for cartons, records, archives, parts, and specialty inventory.
The Often Overlooked 24-Inch Deep Upright
Another interesting aspect of this installation is the use of 24-inch deep upright frames.
Most pallet rack systems are built around standard 40-inch pallets, which is why 42-inch deep upright frames are the most common size found in warehouses today. Because of that, many people assume 24-inch deep uprights are unusual.
While they aren’t as common as 42-inch frames, they’re probably more common than you might think. For applications involving cartons, records, document storage, parts storage, and other non-palletized inventory, a 24-inch deep frame can be an excellent choice.
The reduced depth allows businesses to conserve floor space while still providing substantial storage capacity.
At Midwest Material Handling, we stock both 24-inch and 42-inch deep teardrop upright frames. We also stock wire decking designed to fit our standard 8-foot beam lengths, making it easy to create shelving-style storage systems using pallet rack components.
A Practical Mix of New and Used Pallet Rack
If you look closely at the rack system, you’ll notice several white beams mixed throughout the installation. Those beams were supplied as used inventory that we had available at the time of the project.
While some customers prefer all-new pallet rack with a consistent appearance, others prioritize function, availability, and value. One of the advantages of teardrop pallet rack is its compatibility. New and used components can often be integrated into the same storage system, allowing businesses to expand storage capacity while managing costs.
In this case, the mix of orange and white beams serves as a reminder that warehouse storage systems don’t have to be showroom perfect to be highly effective. The goal is creating a safe, organized, and efficient storage solution that supports the customer’s operation.
Pallet Rack Isn’t Just for Pallets
Projects like this remind us that pallet rack is one of the most versatile storage systems available.
Years ago, we worked with another customer who used pallet rack to store laser discs. If you’re old enough to remember laser discs, you’re probably smiling right now.
The point is that businesses continue to find creative ways to use pallet rack beyond traditional warehouse applications. Whether you’re storing pallets, cartons, records, archived documents, retail inventory, or specialty products, standard teardrop pallet rack can often provide a practical and economical solution.
Sometimes the best storage system isn’t a custom system at all. Sometimes it’s simply using standard pallet rack components in a creative way.
Need Pallet Rack in Cincinnati?
Midwest Material Handling supplies new and used pallet rack throughout Cincinnati, Southwest Ohio and Northern Kentucky.
We stock Husky Rack & Wire teardrop pallet rack components, including upright frames, beams, wire decking, and accessories. Whether you’re storing palletized inventory, cartons, records, archives, or something completely unique, we can help design a storage system that maximizes your available space.
As this project demonstrates, pallet rack isn’t always about pallets. Sometimes it’s about finding a smarter way to store what matters most to your business.
Frequently Asked Questions
Can pallet rack be used for more than pallet storage?
Absolutely. While pallet rack is designed for palletized inventory, many businesses use it to store cartons, records, archives, parts, retail inventory, and other products. With wire decking installed, pallet rack can function as a heavy-duty shelving system.
Why would someone use 24-inch deep pallet rack?
A 24-inch deep upright frame is often a great choice for storing cartons, documents, records, and other non-palletized inventory. The reduced depth helps conserve floor space while still providing substantial storage capacity.
Is 24-inch deep pallet rack common?
While 42-inch deep frames are the most common size used for standard pallet storage, 24-inch deep uprights are more common than many people realize. They are frequently used in shelving-style applications where full pallet depth isn’t required.
Can new and used pallet rack components be combined?
In many cases, yes. One of the advantages of teardrop pallet rack is its compatibility. New and used beams, uprights, and accessories can often be integrated into the same storage system when properly matched and inspected.
What are the benefits of wire decking?
Wire decking provides support for cartons and other products that are not stored on pallets. It improves visibility, promotes airflow, and creates a safer storage surface compared to placing products directly on pallet rack beams.
How can I maximize vertical warehouse space?
One of the most effective ways is to design rack levels around the actual height of your inventory. Minimizing the unused space between storage levels allows businesses to utilize more of the building’s available cube and increase storage density without expanding their footprint.
Looking for a Better Way to Utilize Your Warehouse Space?
Not every storage challenge requires a custom solution.
As this Cincinnati-area vinyl record storage project demonstrates, standard teardrop pallet rack can be used for much more than palletized inventory. Whether you’re storing cartons, records, archives, parts, retail inventory, or specialty products, pallet rack can often provide a practical and cost-effective way to maximize your available space.
Midwest Material Handling stocks new and used Husky Rack & Wire pallet rack, including upright frames, beams, wire decking, and accessories. Our team can help you design a storage system that makes the most of your building’s vertical space while keeping inventory organized and accessible.
Contact Midwest Material Handling today to discuss your storage project and learn how pallet rack can help you increase storage capacity without expanding your facility.
Relocating One of the More Unique Small Parts Storage Systems We’ve Seen in 30+ Years
Warehouses come in all shapes and sizes, but every so often a project stands out from the thousands we’ve encountered over the years. Recently, our team completed a warehouse storage system relocation for a large German based customer involving one of the most unique small parts storage systems we’ve seen in years.
Unlike traditional shelving or static bin storage, this system combined standard pallet racking with a high density hanging bin design that created hundreds of individual storage locations for small parts inventory. The result was an efficient storage solution that maximized warehouse space while providing organized access to a large number of SKUs.
A Unique Approach to Small Parts Storage
This unique storage system, designed and bult in Germany, consisted of large fabric storage modules suspended beneath pallet rack beams using a specialized rail and bracket assembly. Each module was divided into multiple compartments, creating dedicated storage locations for small parts, maintenance supplies, electrical components, hardware and other inventory items.
While the lower levels served as active picking locations, the upper rack levels remained available for reserve inventory storage. This allowed the customer to combine bulk storage and order fulfillment operations within a single racking system.
By utilizing otherwise unused space beneath pallet rack beams, the system delivered exceptional storage density without increasing the facility’s footprint.
Planning the Warehouse Storage System Relocation
Every successful warehouse storage system relocation begins with careful planning. Unlike a standard pallet rack teardown, this project required our team to document and preserve a specialized storage system that relied on custom rail assemblies, adjustable mounting brackets and fabric storage compartments.
The system had been configured around specific inventory locations and picking processes, making organization critical throughout the relocation process.
Our team carefully evaluated:
Existing rack configurations
Rail support systems
Mounting hardware and brackets
Fabric storage modules
Inventory location layouts
Reinstallation requirements
Maintaining organization during disassembly helped ensure a smooth installation process at the new location.
Preserving Inventory Organization
One of the most important aspects of the project was protecting the integrity of the storage layout.
Each compartment within the system represented a designated inventory location. Labels and storage assignments needed to remain organized throughout the move to minimize disruption to warehouse operations.
By documenting storage locations and maintaining component organization during the relocation process, the customer was able to restore inventory functionality more efficiently after installation.
Specialized Rack Mounted Design
What made this project particularly unique was the integration of the storage modules directly into the pallet racking system.
The hanging compartments were supported by rail assemblies mounted beneath the pallet rack beams. Adjustable brackets allowed the rails to be securely attached while supporting the weight of the storage modules and inventory.
This design transformed conventional pallet racking into a highly organized small parts picking system capable of supporting hundreds of individual inventory locations.
For facilities managing large numbers of SKUs, this approach provides a practical alternative to extensive shelving systems while making better use of available warehouse cube.
Benefits of High Density Small Parts Storage
Systems like this continue to gain popularity because they offer several operational advantages.
Increased Storage Density
By utilizing vertical space within existing pallet rack structures, businesses can significantly increase storage capacity without expanding their warehouse footprint.
Improved Inventory Control
Dedicated storage compartments help reduce misplaced inventory and improve location accuracy.
Faster Order Picking
Clearly defined storage locations allow employees to quickly locate and retrieve inventory items.
Efficient Use of Existing Racking
Rather than adding additional shelving rows, facilities can leverage existing pallet rack structures to create hundreds of additional pick locations.
Why Experience Matters
Warehouse relocation projects often involve more than simply moving equipment from one building to another. Specialized systems require careful planning, documentation and installation expertise to ensure they continue performing as intended after the move.
Projects involving pallet racking, storage systems, shelving and inventory management equipment benefit from experienced material handling professionals who understand both the structural and operational requirements of the system.
In this case, preserving the functionality of a highly customized storage solution was just as important as relocating the physical equipment itself.
Final Thoughts…
After more than three decades in the material handling industry, it takes a lot for a storage system to stand out. This project certainly did.
The combination of pallet racking, suspended storage modules and high density inventory organization created one of the most unique small parts storage systems we’ve encountered. Successfully completing the warehouse storage system relocation required careful planning, detailed organization and a thorough understanding of how the system functioned within the customer’s operation.
For warehouses seeking to maximize space utilization and improve small parts inventory management, specialized storage solutions like this demonstrate how creative design can transform conventional racking into a highly efficient storage and picking system.
Need Help With a Warehouse Storage System Relocation?
Whether you’re relocating pallet racking, shelving, storage equipment or a specialized inventory system, Midwest Material Handling can help evaluate, disassemble, relocate and reinstall warehouse storage systems throughout Ohio and the surrounding region.
Our experienced team has worked with everything from standard pallet rack systems to highly customized storage solutions designed for unique inventory requirements.
Contact Midwest Material Handling to discuss your upcoming warehouse relocation project and learn how we can help keep your operation organized, efficient and productive throughout the process.
Most companies can identify a dock leveler with a serial number. We can identify them when the serial number is gone.
If you work around older loading docks long enough, you eventually run into the same frustrating situation: a dock leveler breaks down, replacement parts are needed quickly, and the serial plate is either unreadable or completely missing.
More times than not, this is exactly what we see in the field.
At Midwest Material Handling, we help customers identify replacement components through our Wholesale Dock Leveler Parts page every day. While a manufacturer name, model number, capacity, and serial number are always the easiest way to identify dock leveler parts, the reality is that many older dock levelers no longer have usable identification plates.
That is where experience matters.
For more than 30 years, we have worked on and identified old dock levelers throughout warehouses, trucking terminals, manufacturing facilities, and distribution centers across Ohio. After seeing tens of thousands of dock levelers over the years, many older manufacturers, spring configurations, hinge designs, and hydraulic layouts become recognizable even when no serial plate exists.
Identifying dock leveler parts without serial numbers requires experience, not just guessing.
How Do We Do It?
After more than 30 years working around loading dock equipment, many older dock levelers become recognizable even when the serial plate is gone.
We identify older dock levelers by studying the overall construction and component layout. Certain manufacturers used distinctive hinge designs, spring configurations, hydraulic layouts, linkage systems, and structural patterns that become familiar after seeing thousands of dock levelers over the years.
We also maintain a large library of older dock leveler manuals and parts breakdowns covering many legacy manufacturers and model series dating back decades.
When we combine that documentation with real-world field experience, we can often narrow down the manufacturer and identify the correct replacement parts even when little identifying information still exists on the dock leveler itself.
That is the value experience brings to dock leveler parts identification.
Serial Numbers Are Still the Best Starting Point
When a dock leveler still has a clean and readable serial plate, that is usually the fastest and most accurate way to identify replacement parts. The manufacturer, model number, capacity, and serial number can often narrow things down quickly.
Unfortunately, older dock levelers rarely make things that easy. Over the years, serial plates are commonly rusted beyond recognition, painted over, damaged during repairs, or simply knocked off entirely. Many manufacturers originally attached these plates using small rivets, so after decades of forklift traffic, vibration, maintenance work, and weather exposure, they often disappear completely.
That is when hands-on dock equipment experience becomes extremely valuable.
Before You Can Identify the Part, You Have to Identify the Dock Leveler
One of the biggest misconceptions in the loading dock industry is that replacement parts can simply be matched visually.
In reality, properly identifying dock leveler parts usually starts with identifying the dock leveler itself. That becomes difficult when the manufacturer is unknown, the serial plate is gone, or the dock leveler has been repaired multiple times over the years using non-original parts.
This is where experience makes a major difference.
By studying the overall dock leveler construction, hinge layouts, spring configurations, hydraulic systems, linkage assemblies, and safety components, we can often narrow down the original manufacturer and approximate model series even when no identification plate exists.
Once the dock leveler itself is identified, we can usually identify the correct replacement parts much more accurately.
30+ Years of Experience Identifying Old Dock Levelers
Anyone can identify a dock leveler when the serial plate is perfectly readable. The real challenge is identifying older dock equipment that may be 20 to 50 years old with little or no usable information remaining.
At Midwest Material Handling, we have spent decades working around older loading dock equipment throughout Ohio. Over time, many dock leveler designs become recognizable simply through field experience. Certain manufacturers used very distinctive hinge designs, spring layouts, hydraulic arrangements, and structural patterns that become familiar after seeing thousands of units over the years.
This is one of those industries where old-school experience still matters.
A Large Library of Older Dock Leveler Manuals
One of the biggest advantages of working with an experienced dock equipment company is access to older documentation that many companies no longer have.
Over the years, we have built a large library of older dock leveler manuals, parts breakdowns, and manufacturer documentation covering many legacy dock leveler brands dating back decades. That information becomes extremely valuable when trying to identify older spring assemblies, hold down mechanisms, hydraulic components, lip hinge systems, and structural repair parts.
In many cases, combining older manuals with real-world field experience allows us to identify dock leveler parts even when the original serial plate no longer exists.
Common Dock Leveler Manufacturers We Help Identify
Over the years, we have worked with and identified replacement parts for many older dock leveler manufacturers and legacy loading dock brands. Even when serial plates are missing, certain hinge designs, spring layouts, hydraulic systems, and structural details often help narrow down the original manufacturer.
Some of the most common dock leveler brands we help identify include:
Kelley
Serco
Rite Hite
Blue Giant
McGuire
Nordock
Pentalift
Poweramp
DLM
Advance Lifts
Beacon
Copperloy
Chalfant
Loading Systems
Vestil
Many of these manufacturers produced multiple dock leveler styles and model series over several decades, which is why hands-on experience and older manuals can become extremely valuable when trying to identify the correct replacement parts.
Even if the dock leveler manufacturer is unknown, good underside photos and measurements often help us narrow things down quickly.
Photos Help Us Identify Older Dock Levelers
When serial numbers are missing, good photos become one of the most valuable tools in the identification process.
Clear underside photos often tell us far more than people realize. Certain manufacturers used distinctive frame designs, rear hinges, lip hinges, spring arrangements, and hydraulic layouts that help narrow down the original dock leveler manufacturer and approximate model series.
Even heavily modified dock levelers usually leave enough structural clues behind to point us in the right direction.
Sometimes we can identify a dock leveler almost immediately from a few underside photos simply because we have seen similar units so many times over the years.
Measurements Matter More Than Most People Realize
Measurements often play a major role when identifying older dock leveler parts correctly.
For example, when identifying a mechanical dock leveler main spring, the overall spring length and diameter are important, but the coil count is often one of the biggest factors. Two springs may appear almost identical visually, but a different number of coils can completely change the spring tension and how the dock leveler operates.
The same concept applies to hydraulic cylinders, hold down assemblies, hinge spacing, and linkage components. Small dimensional differences can dramatically affect dock leveler performance and safety.
In some cases, previous owners may have installed incorrect replacement parts years earlier, which creates another layer of complexity when trying to identify the proper components today.
That is why identifying dock leveler parts often requires much more than simply matching components by appearance alone.
Mechanical and Hydraulic Dock Levelers Are Identified Differently
Mechanical dock levelers and hydraulic dock levelers often require completely different identification methods.
Mechanical units are commonly identified through spring configurations, hold down assemblies, linkage systems, and release mechanisms. Hydraulic dock levelers are more commonly identified using cylinder dimensions, hydraulic hose layouts, pump assemblies, and power unit styles.
Because many older dock levelers have been repaired multiple times over the years, identifying the original configuration often requires evaluating the entire dock leveler instead of focusing only on the damaged component.
Replacement Parts Keep Older Dock Levelers Operating
Many older dock levelers were heavily built and designed for long service life.
In many situations, replacing worn springs, cylinders, hold downs, hydraulic hoses, or structural components allows facilities to continue operating existing dock equipment safely for years.
The key is correctly identifying the replacement parts needed, especially when serial numbers or model information no longer exist.
That is where experience and documentation become extremely important.
A Broken Dock Leveler Can Create Major Downtime
Many facilities operate with limited dock positions, so even one broken dock leveler can quickly create shipping delays, receiving bottlenecks, forklift safety concerns, and warehouse inefficiencies.
Correctly identifying replacement parts quickly helps minimize downtime and keeps freight moving safely. Many common dock leveler parts are available with overnight or second day shipping depending on availability.
Why Customers Choose Midwest Material Handling for Dock Leveler Parts
The biggest value we provide is not simply selling dock leveler parts.
The value comes from helping customers identify older dock levelers and locate the correct replacement components when no serial number exists, the manufacturer is unknown, or the dock leveler has been modified repeatedly over decades of service.
That combination of 31+ years of field experience, hands-on dock equipment knowledge, a large library of older dock leveler manuals, and real-world repair experience allows us to solve problems that are often difficult to figure out through catalogs or online searches alone.
This is something we do every day.
Dock Leveler Parts Identification Form
To help streamline the identification process, we also offer a Dock Leveler Parts Identification Form where customers can upload photos and provide measurements for older dock levelers.
Even when the serial number is gone or the identification plate is unreadable, we can often narrow down the correct replacement parts using photos, measurements, manuals, and overall dock construction details.
The more information provided, the faster we can usually help identify the correct components.
Need Help Identifying an Old Dock Leveler?
If your dock leveler serial plate is missing or unreadable, send us a few photos of the dock leveler underside, springs, cylinders, hinges, or damaged components and we can usually help identify the replacement parts needed.
While serial numbers are always helpful, the reality is that many older dock levelers no longer have them. Fortunately, identifying older dock equipment is something we have been doing for decades.
Frequently Asked Questions
Can you identify a dock leveler without a serial number?
Yes. Many older dock levelers can still be identified using underside photos, spring configurations, hinge styles, hydraulic layouts, and structural details.
Why are dock leveler serial plates often missing?
Many serial plates were originally attached with small rivets and were eventually knocked off after decades of forklift traffic, vibration, repairs, weather exposure, and repainting.
What photos help identify dock leveler parts?
Photos of the underside, rear hinges, lip hinges, springs, hydraulic cylinders, damaged parts, and power units are usually the most helpful.
What measurements help identify dock leveler springs?
Spring diameter, overall spring length, and especially the coil count are often important when identifying replacement springs for older mechanical dock levelers.
Can older dock levelers still be repaired safely?
In many cases, yes. Older dock levelers were often heavily built and can continue operating safely for years with the proper replacement parts and repairs.
How fast can dock leveler parts ship?
Many common dock leveler parts are available with overnight or second day delivery depending on stock and location.
Installing an Edge of Dock Leveler (EOD) on an Old Dock
Installing an edge of dock leveler (commonly shortened and referred to as an “EOD”) on an older loading dock can sometimes become a challenge, especially when the dock was never constructed with embedded steel angle coping at the dock edge. Many older warehouse docks simply do not have a proper steel mounting surface where an EOD can be welded securely.
Fortunately, there is a simple retrofit solution that has been used for years: the EOD steel approach plate.
While approach plates are fairly simple in design, they solve an important structural problem. They provide the steel surface needed to properly weld an edge of dock leveler onto older docks that otherwise have nowhere suitable to attach one.
Despite their relatively simple design, edge of dock levelers remain a popular loading dock solution because they can typically service trailers up to 15″ above and 15″ below dock height while avoiding the cost of a full pit-style dock leveler installation.
Over the years, we supplied many of these retrofit approach plates for warehouse and loading dock applications involving older edge of dock levelers. Although we no longer install these systems today, approach plates still remain an effective solution for facilities replacing aging EOD equipment or evaluating difficult dock edge conditions. Steel approach plates are a standard item in our complete replacement wholesale dock leveler parts and components page.
What Is an EOD Approach Plate?
An approach plate is a steel transition plate used when installing an edge of dock leveler on an older loading dock that lacks embedded steel angle coping.
The plate creates a weldable steel mounting surface for the EOD while also providing a smoother transition for forklifts entering the leveler.
In most applications, approach plates are fabricated from 1/4″ thick checkered steel plate and commonly measure around 12″ deep by 10′ wide.
The leading edge of the plate is chamfered or tapered downward so loaded forklifts and pallet jacks can smoothly roll onto the edge of dock leveler without striking a sharp steel edge.
Approach plates are commonly used on older warehouse docks where the original concrete dock edge was never designed to support direct EOD installation.
Why Older Loading Docks Create Problems for EOD Installation
Modern loading docks are commonly constructed with embedded steel angle coping at the dock edge. This coping is typically fabricated from a 3″ x 3″ piece of structural steel angle cast directly into the concrete.
The embedded angle creates a durable steel edge where dock equipment can be welded securely.
To help lock the angle into the concrete structure, mud hooks are welded onto the back side of the steel before the concrete is poured. These mud hooks are usually pieces of rebar bent into hook shapes. Once surrounded by concrete, they help prevent the embedded steel from shifting or pulling loose over time.
Many older docks, however, were built without embedded angle coping altogether. In those situations, installers are left with nothing but a raw concrete dock edge.
That becomes a problem because edge of dock levelers are not designed to simply be bolted down across the top mounting surface.
Why Edge of Dock Levelers Must Be Welded!
An edge of dock leveler is designed to be welded along the upper mounting edge. This welded connection is critical for long-term stability.
During normal warehouse operations, loaded forklifts repeatedly travel across the leveler while moving freight in and out of trailers. That constant movement creates vibration, impact and dynamic loading forces at the dock edge.
If an EOD were only secured with anchors across the top surface, the installation would eventually loosen after repeated use.
Instead, the upper section of the EOD is welded directly to structural steel at the dock edge.
The only anchors typically used on an edge of dock leveler installation are located at the lower bumper block assemblies. Those anchors secure the bumper blocks into the face of the concrete dock.
Without a weldable steel surface at the top edge, a proper EOD installation becomes very difficult on older dock structures.
Why Edge of Dock Levelers Are Still Common on Older Docks
One reason edge of dock levelers remain popular on older loading docks is their ability to handle a fairly wide working range while still being more economical than many full-size pit levelers.
Most EODs provide a working range of approximately 15″ above dock height and 15″ below dock height. This allows the leveler to service a variety of trailer heights during normal loading operations.
That operating range is important because older warehouse facilities often deal with varying trailer conditions, changing truck suspension heights and uneven parking areas. An EOD provides enough flexibility for many standard loading applications without requiring a full dock leveler pit installation.
How an Approach Plate Solves the Problem
An approach plate creates the steel mounting surface needed for the EOD installation.
The plate is anchored from the top side of the dock and positioned directly behind the edge of dock leveler. The EOD can then be welded directly to the plate itself.
In most applications, the approach plate is fabricated from 1/4″ thick checkered steel plate and commonly built around 10 feet wide.
While some assume thicker steel is automatically better, that is not always true in this application.
Excessively thick plate can create too steep of a transition angle for forklifts entering the leveler. In many cases, 1/4″ plate provides the best balance between durability and smooth forklift entry.
The Chamfered Edge Is An Important Part
Although the plate itself is fairly straightforward, the chamfered leading edge is what makes the system work properly. Without it, the approach plate is really no more than a standard piece of checkered plate steel.
The chamfer creates a gradual transition from the warehouse floor onto the approach plate and edge of dock leveler. Without it, loaded forklifts and pallet jacks can strike a hard steel edge while entering the EOD (or can actually totally prevent the forklift or pallet jack from rolling over the plate, particularly when fully loaded).
By tapering the front edge downward, forklifts can smoothly roll onto the leveler during loading operations.
Ironically, chamfering the plate is often the most difficult and labor-intensive part of the fabrication process.
Aside from the chamfered edge, the plate is essentially a flat piece of 1/4″ checkered steel. But producing a smooth tapered edge across a wide plate requires careful fabrication and finishing.
It is a relatively simple solution to a challenging dock problem.
Angle Coping vs. Structural C-Channel
Traditional dock edge coping is commonly fabricated from 3″ x 3″ steel angle embedded into the dock edge.
However, in many applications, structural C-channel actually performs better than standard angle coping.
With C-channel, the steel extends farther down the face of the dock depending on the depth of the channel. This creates a larger and more stable structural surface for dock equipment installation.
Like angle coping, embedded C-channel also uses welded mud hooks to lock the steel securely into the concrete during the pour.
In heavy-use loading dock applications, C-channel often provides a stronger and more durable dock edge than standard angle coping.
A Simple Retrofit Solution That Still Works
Many older warehouse docks throughout the country still lack embedded steel coping. When edge of dock levelers need replacement or retrofit installation, approach plates remain a practical and effective solution.
Despite their simple appearance, these plates solve several important problems at once:
They create a weldable steel mounting surface
They improve forklift transition onto the EOD
They help stabilize the installation long term
They allow older docks to continue using edge of dock equipment safely
Sometimes the simplest industrial solutions are also the most effective.
Need Replacement Dock Leveler Parts?
Older loading docks often require creative retrofit solutions, especially when replacing aging edge of dock levelers or dock bumpers. Midwest Material Handling supplies a variety of dock leveler parts and loading dock equipment components for warehouse facilities throughout Ohio and beyond.
Whether you are replacing worn dock bumpers, upgrading an older EOD or evaluating a difficult dock edge condition, understanding how the original dock was constructed is an important first step.
Frequently Asked Questions
What is an approach plate for an edge of dock leveler?
An approach plate is a steel plate installed behind an edge of dock leveler to create a weldable mounting surface on older docks that lack embedded steel angle coping.
Why can’t an edge of dock leveler simply be bolted down?
Edge of dock levelers experience constant forklift traffic and impact loading. Without a welded top connection, the installation can loosen over time. The upper portion of the EOD is designed to be welded to structural steel.
What thickness is typically used for an EOD approach plate?
Most approach plates are fabricated from 1/4″ thick checkered steel plate. Thicker steel is not always better because it can create too steep of a transition angle for forklifts.
What is angle coping on a loading dock?
Angle coping is embedded structural steel installed along the edge of a loading dock. It is commonly fabricated from 3″ x 3″ steel angle and provides a durable weldable edge for dock equipment.
What are mud hooks?
Mud hooks are pieces of rebar bent into hook shapes and welded onto embedded steel coping before concrete is poured. They help lock the steel securely into the dock structure.
Why is the chamfered edge important on an approach plate?
The chamfered edge creates a smoother transition for forklifts entering the edge of dock leveler. Without the taper, forklifts and pallet jacks can strike the edge of the steel plate during loading operations.
What is the working range of an edge of dock leveler?
Most edge of dock levelers have an operating range of approximately 15″ above dock height and 15″ below dock height, allowing them to service a variety of trailer heights during normal warehouse loading operations.
Secure Wire Partition Installation for an Ohio Server Hosting Facility
When companies need to separate secure areas inside sensitive environments, wire partition systems offer a practical solution that combines visibility, airflow, and controlled access. Midwest Material Handling recently completed a specialized wire partition installation inside a secure server hosting facility in Dublin, Ohio where multiple organizations maintained hosted equipment and infrastructure within the same building.
The project involved furnishing and installing a WireCrafters wire partition system designed to separate customer server areas inside an active data environment. In addition to the wire partition system itself, the project also included a secured entry opening with a magnetic door lock assembly to support controlled access into the partitioned area.
Unlike a traditional warehouse installation, this project required extensive coordination, material handling, and installation flexibility due to the highly controlled nature of the facility.
While Midwest Material Handling is widely known for supplying warehouse racking and industrial storage systems in Ohio, the company also furnishes and installs specialized wire partition systems for secure commercial and industrial environments.
Working Inside a Live Server Environment
The fourth-floor server room installation took place inside a secure commercial facility in Dublin, Ohio where maintaining airflow and protecting active infrastructure were critical throughout the project.
The server room featured a raised access flooring system with perforated floor panels that allowed cooled air to circulate upward into the server equipment below. Because the facility remained active throughout the installation process, protecting the cooling system and surrounding equipment became a major priority during the project.
Installing the wire partition posts required drilling through the raised flooring system. However, drilling directly inside the server room could have introduced metal shavings and debris into the cooling airflow system beneath the floor.
To avoid contamination concerns, our crew carefully removed individual 24″ x 24″ perforated floor panels and transported them outside the building for drilling. Once the holes were completed, the panels were brought back into the facility and reinstalled before the partition posts were secured in place.
The process added significant labor and coordination to the installation, but it allowed the project to move forward without disrupting the facility’s sensitive operating environment.
Full Material Handling and Installation Coordination
This installation also required a level of onsite logistical support that extended well beyond a typical wire partition project.
Due to the security-sensitive nature of the facility, the customer requested that Midwest Material Handling handle the unloading and material movement process entirely. One of our installers remained onsite at the loading dock awaiting the scheduled LTL shipment containing the WireCrafters partition components.
Once the shipment arrived, our crew unloaded the delivery using our own forklift equipment and mobilized all materials throughout the facility. The wire partition components were then transported up to the fourth-floor server room installation area where staging and installation took place.
By handling the unloading, transportation, staging, and installation internally, the customer’s staff was able to remain focused on facility operations while our crew managed the project from start to finish.
Wire Partition Security Features and Access Control Options
Wire partition systems are commonly used in server rooms, colocation environments, and technology facilities because they provide physical separation while still allowing airflow, visibility, and light transmission throughout the space.
Unlike solid walls, wire partitions help maintain airflow circulation which is especially important in environments that rely on controlled cooling systems.
Wire partition systems can also be configured with a variety of security and access control options including:
Hinged access doors
Sliding security doors
Magnetic door locks
Card reader integration
Electronic access control hardware
Ceiling panels and secured enclosures
Custom partition layouts
For this project, the secured opening was designed to accommodate a magnetic locking system furnished by Midwest Material Handling while a separate security contractor completed the final wiring and access control integration.
Installation Flexibility for Specialized Commercial Environments
Every facility presents different installation challenges. While some projects involve traditional warehouse environments, others require coordination inside operating manufacturing facilities, server rooms, healthcare buildings, or high-security commercial spaces.
Midwest Material Handling regularly works with customers to coordinate equipment installations around operational requirements, delivery schedules, security procedures, and facility access limitations.
Whether the project requires after-hours installation, specialized unloading coordination, material staging, or careful work inside sensitive operating environments, our team can help manage the process from delivery through final installation.
Due to the secure nature of this facility, photography inside the server environment was not permitted. However, the completed installation provided separated secured areas for hosted customers while maintaining compatibility with the facility’s airflow and cooling system design.
Wire Partition Systems and Security Enclosures in Ohio
Midwest Material Handling provides wire partition systems and installation services throughout Ohio for commercial and industrial applications including:
Server rooms and data environments
Warehouse security cages
Tool cribs
Inventory protection areas
Tenant storage separation
Manufacturing security enclosures
Maintenance storage areas
High-value equipment protection
We offer complete project support including layout assistance, product sourcing, delivery coordination, unloading support, and professional installation services.
Request a Quote for Wire Partition Systems in Ohio
If your facility needs a wire partition system, secured enclosure, or controlled access solution, Midwest Material Handling can help design and install a system that fits your application.
From warehouse security cages to specialized server room partition installations, our team can assist with product selection, access control options, and complete installation coordination throughout Ohio.
Contact Midwest Material Handling today to discuss your custom project.
Frequently Asked Questions
What are wire partition systems used for?
Wire partition systems are commonly used to create secured areas inside warehouses, server rooms, manufacturing facilities, and commercial buildings. They help separate inventory, equipment, tools, or customer spaces while maintaining visibility and airflow.
Can wire partitions be used in server rooms or data centers?
Yes. Wire partition systems are often used in server rooms and colocation facilities because they provide security while still allowing airflow circulation throughout the environment.
Do wire partition systems support electronic access control?
Yes. Wire partition systems can be configured with magnetic door locks, electric strikes, card readers, keypad access systems, and other electronic security hardware.
Does Midwest Material Handling provide installation services for wire partitions?
Yes. Midwest Material Handling provides delivery coordination, unloading assistance, material staging, and professional installation services for wire partition systems throughout Ohio.
Can wire partition systems be customized?
Yes. Wire partition systems are available in many configurations including full-height enclosures, ceiling panels, sliding doors, hinged doors, and custom layouts designed around the customer’s facility. While these partition components are stocked in standard or the most common sizes, any configuration is possible, simply inquire.
Do you install wire partitions in active facilities?
Yes. Many projects take place inside active operating facilities where coordination, scheduling, and careful installation procedures are required to minimize disruption to ongoing operations.
Ohio Public Charter School Creates Mock Warehouse Using Pallet Racking for Forklift Training
Every once in a while we run into a project that is a little different from the normal warehouse installation. This was one of them.
Recently, Midwest Material Handling worked with an Ohio public charter high school that is launching a forklift and logistics training program for students interested in warehouse, distribution and material handling careers. Instead of creating a simple practice area with a forklift and a few pallets, the school wanted to build something much more realistic, a functioning mock warehouse environment where students could train around actual pallet racking systems and warehouse equipment.
Honestly, it was one of the more unique applications we have seen.
The tuition free charter school operates seven campuses throughout Ohio and offers students an alternative to traditional high school programs. As part of a new workforce development initiative, they created a dedicated forklift and logistics program led by an instructor whose full time role focuses specifically on warehouse operations, forklift safety and logistics training.
The idea behind the project was simple: give students exposure to a real warehouse environment before entering the workforce.
To help make that happen, the school purchased a large quantity of pallet racking including 12 foot uprights, standard 8 foot beams and wire decking to build multiple storage rows inside the training area. They also added post protectors and row spacers to create layouts similar to what students would encounter in an actual warehouse or distribution facility.
Seeing the finished setup in person was impressive. Rather than creating a small practice area, the school built a realistic warehouse layout designed to mirror actual distribution and logistics environments.
One detail that stood out to us was the addition of steel fork extensions for the training forklift. The forklift currently has standard 42 inch forks, so the school selected 63 inch fork extensions that allow students to safely unload pallet racking from the back of a box truck during training exercises.
The extensions also became part of the learning experience itself. Since the forklift will be used strictly for training purposes, the instructor wanted students to gain exposure to different forklift configurations and understand how longer forks affect load handling and equipment operation.
What is the Goal of the Pilot Program?
Unlike a traditional classroom setup, this training environment allows students to operate equipment around real pallet rack aisles, maneuver through warehouse layouts and gain familiarity with warehouse safety practices before entering the workforce.
With warehousing and logistics continuing to grow throughout Ohio, trained forklift operators remain in high demand. Programs like this help students build practical skills while giving local employers access to better prepared entry level workers.
This installation currently serves as a pilot program, with plans to potentially expand similar training setups to additional campuses over the next year.
Projects like this are a reminder that storage racking systems are not always used strictly for storage. In this case, the equipment became part of a hands on educational environment focused on safety, workforce development and real world warehouse training.
Equipment Included in the Project
The training warehouse included:
12 foot pallet rack uprights
Standard 8 foot pallet rack beams
Wire decking
Post protectors
Row spacers
63 inch steel fork extensions
Why Create a Mock Warehouse for Forklift Training?
The school’s goal was to simulate realistic warehouse conditions where students could become comfortable working around actual storage systems and material handling equipment.
This type of environment helps students gain experience with:
Forklift aisle navigation
Load handling
Rack awareness and clearance
Equipment safety procedures
Fork extension operation
Warehouse traffic flow
General warehouse logistics concepts
For many students, this may be their first exposure to a real warehouse style environment before entering the workforce.
Why Choose Midwest Material Handling?
Midwest Material Handling supplies new and used pallet racking systems, wire decking, rack protection products and material handling equipment throughout Ohio. We work with warehouses, manufacturers, schools and distribution facilities to create practical storage and equipment solutions designed around each application.
Whether you are building a warehouse, expanding storage capacity or creating a specialized training environment, our team can help you select the right equipment for the job.
Frequently Asked Questions
Can pallet racking systems be used for forklift training programs? Yes. Pallet racking systems are commonly used to create realistic warehouse training environments where students can practice forklift operation, load handling and warehouse navigation.
Why would a school build a mock warehouse? >>>>>>>>>>>Creating a realistic warehouse environment helps students gain hands on experience working around pallet racking systems, forklifts and warehouse layouts before entering the workforce.
What are forklift fork extensions used for? >>>>>>>>>>>Fork extensions increase the usable fork length on a forklift, allowing operators to safely handle longer loads when used properly within equipment capacity limits.
What are row spacers used for in pallet racking systems? Row spacers connect back to back pallet rack rows while maintaining consistent spacing and improving row stability.
Get Help With Warehouse Equipment and Pallet Racking
Planning a warehouse project, training facility or pallet rack installation in Ohio? Midwest Material Handling supplies new and used pallet racking, wire decking, rack protection products and material handling equipment for a wide range of industrial applications. Contact our team to discuss your project requirements and layout needs.
Vertical Bar Racks: A Simple Solution for Long Material Storage
Storing long materials can become frustrating quickly. Pipe, conduit, wood trim and bar stock often end up leaning against walls or stacked across shelves where they become difficult to organize and access. While some companies use larger warehouse storage systems like cantilever racking for long material storage, many applications simply require a practical way to keep materials upright, separated and easy to reach throughout the workday.
A vertical bar rack works well for storing:
conduit and tubing
PVC and steel pipe
wood trim and molding
baseboard and handrail
round bar and rod stock
aluminum extrusion
lumber and woodworking materials
Because materials are stored vertically, these racks use very little floor space while still allowing employees to quickly identify and access products. They are commonly used in maintenance departments, fabrication shops, woodworking operations and warehouse supply areas where materials are handled manually.
Popular in Wood Shops & Vocational Schools
Over the past few weeks, Midwest Material Handling has even received calls from high schools looking for better ways to organize materials inside wood shop classrooms and vocational training areas. In many of these applications, a vertical bar rack makes more sense than building custom shelving or adapting pallet racking for lighter wood materials.
The simple design keeps long boards and trim pieces organized without taking up large amounts of wall space. It also helps students and instructors separate materials by size or type while keeping the work area cleaner and easier to manage.
Ideal for Trim, Molding & Interior Finish Materials
A vertical bar rack is also a great fit for companies that work with interior finish products like baseboard, quarter round, casing and handrail. Long trim pieces can become difficult to sort when they are stacked horizontally, especially when multiple profiles and lengths are involved.
Vertical storage makes it easier to identify products, separate materials and access inventory throughout the day without creating clutter around the workspace. For companies that manually handle trim materials, the setup is simple and efficient.
Why Some Companies Prefer a Vertical Bar Rack
While pallet racking and cantilever rack systems can also be used for storing long materials, many customers prefer a welded vertical bar rack because it is straightforward and easy to use. These racks require very little setup, fit well in smaller spaces and work especially well for applications where forklifts are not needed.. These racks require very little setup, fit well in smaller spaces and work especially well for applications where forklifts are not needed.
Many models are designed to sit directly against a wall near active work areas. Longer products are stored vertically inside individual bays, while shorter items and accessories can be stored on lower shelves below.
Depending on the model, features may include restraint chains for each storage bay, lag-down mounting points for additional stability and raised storage arms that help prevent round materials from rolling out during use. Most units are built from heavy-duty steel and finished with a durable industrial coating designed for long-term use.
For lighter-duty industrial applications, some vertical bar rack models offer capacities up to 3,000 pounds when loads are evenly distributed.
Practical Storage Without Overcomplicating the System
For businesses, schools, maintenance departments and woodworking operations, a vertical bar rack offers a simple and cost-effective way to store long materials without overcomplicating the storage system. In many applications, the easiest storage solution is still the best one.
Need Help Choosing the Right Vertical Bar Rack?
Midwest Material Handling supplies vertical bar racks and long material storage solutions for warehouses, fabrication shops, maintenance departments, woodworking operations and educational facilities throughout Ohio. Whether you are storing conduit, pipe, trim materials or lumber, we can help you determine the right storage solution for your application and available floor space.
Contact Midwest Material Handling for pricing, availability and assistance selecting the right vertical storage rack for your facility.
Frequently Asked Questions
What is a vertical bar rack used for?
A vertical bar rack is used to store long materials upright in a compact footprint. Common applications include storing conduit, pipe, lumber, trim pieces, tubing, bar stock and other long materials that are manually handled throughout the day.
Can a vertical bar rack store wood trim and molding?
Yes. Vertical bar racks are commonly used for storing baseboard, quarter round, casing, crown molding and handrail products. Vertical storage makes it easier to organize different profiles and lengths without stacking materials horizontally.
Are vertical bar racks good for school wood shops?
Yes. Vertical bar racks are a practical storage solution for vocational schools and wood shop classrooms because they keep lumber and woodworking materials organized while using minimal floor space.
Can pallet racking be used for vertical material storage?
Yes. Pallet racking can sometimes be configured for vertical storage using dividers or custom sections. However, many companies choose a dedicated vertical bar rack because it is simpler, more compact and easier to manage for lighter-duty applications.
Do vertical bar racks need to be anchored?
Many vertical bar rack models include lag-down points so the unit can be secured to the floor for additional stability. Proper anchoring recommendations may vary depending on the application and load requirements.