Midwest Material Handling, LLC

Pallet Racking and Warehouse Storage Specialists

Old-Fashioned Service. Honesty. Integrity... Since 1995

Pallet Racking and Warehouse Storage Specialists

Old-Fashioned Service. Honesty. Integrity... Since 1995

Author name: Midwest MH

Vertical Bar Rack by Vestil Manufacturing

Vertical Bar Rack for Pipe, Conduit & Lumber Storage

Vertical Bar Rack by Vestil Manufacturing   Vertical Bar Rack by Little Giant Vertical Bar Rack by Vestil Manufacturing

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.

Vertical Bar Rack by Little Giant

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.

Vertical Bar Rack by Vestil Manufacturing

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.

Vertical Bar Rack for Pipe, Conduit & Lumber Storage Read More »

Diagram showing pallet racking under 12 feet versus over 12 feet and how it relates to high-piled storage requirements in Ohio

Do You Need a Permit for Pallet Racking in Ohio? The Real Answer.

Diagram showing pallet racking under 12 feet versus over 12 feet and how it relates to high-piled storage requirements in Ohio

Do You Need a Permit for Pallet Racking in Ohio? Here are the Facts.

If you’re installing pallet racking in Ohio, you’ve probably heard completely different answers about permits. Some companies say you always need one. Others say you dont.

After 31+ years selling and installing pallet racking across Ohio, here’s the reality: Most standard pallet racking installations never go through a formal permit process.

But there’s a reason for the confusion, it comes down to how the fire code is written versus how it’s actually applied in the real world.

This guide breaks down both.


How It Actually Works in the Real World

Across most of Ohio, pallet racking projects are installed without formal permits.

That’s not because there isn’t a fire code. There is. It’s because most standard warehouse setups don’t trigger the conditions that typically lead to review.

Where things change is when storage height, product type, or layout increases fire risk. That’s when a project is more likely to get attention from a fire official.


What the Fire Code Says (And Why It Matters)

Ohio follows the Ohio Fire Code, which is based on the International Fire Code (IFC).

The part that affects pallet racking is called high-piled storage. This generally refers to storing combustible materials where the top of storage exceeds about 12 feet. The code outlines additional requirements, including permits and plan review, for those conditions.

Here’s the part most people misunderstand: It’s not about how tall your rack is… it’s about how high your product is stored.


Real-World Examples

  • A 20-foot rack storing product at 10 feet → typically not high-piled storage
  • A 10-foot rack storing product at 13 feet → considered high-piled storage

The fire code is focused on fuel load, vertical fire spread, and sprinkler performance, not the steel itself.


Why the 12-Foot Threshold Matters

As storage height increases, fire behavior changes. Heat builds faster. Fire spreads vertically more aggressively. Sprinkler systems become more sensitive to layout and clearance.

That’s why projects with taller storage are more likely to be reviewed, especially if other risk factors are present.


When a Project Is More Likely to Be Reviewed

Most installations don’t draw attention. But certain conditions make review more likely:

  • Storage heights approaching or exceeding about 12 feet
  • Plastic or higher-risk commodities
  • Layouts that impact sprinkler performance
  • Larger systems or major layout changes

These are not automatic triggers, they’re the situations where a fire official is more likely to take a closer look.


Why It Varies by Location

The fire code itself is consistent across Ohio. What varies is enforcement.

Some areas, especially those with a high concentration of distribution and warehouse facilities, like Groveport Ohio and parts of Columbus, tend to review projects more closely. Other areas are less hands-on unless something stands out.

Same code. Different levels of scrutiny.


What Inspectors Actually Care About

If a project does get reviewed, the focus is usually on:

  • Flue spacing
  • Aisle widths
  • Commodity classification
  • Sprinkler clearance
  • Anchoring and overall layout

These are the same factors that should already be addressed in a properly designed rack system.


A Practical Rule of Thumb

If your storage is relatively low and straightforward, you will likely never deal with a formal permit process.

If your storage is taller, involves plastics, or interacts heavily with your sprinkler system, it’s worth taking a closer look.

Not because you automatically need a permit, but because those are the situations where questions tend to come up.


Quick Checklist: Will Your Project Get Reviewed?

Most projects never check these boxes, but when they do, that’s when questions usually come up.

  • Is your stored product approaching or exceeding about 12 feet?
  • Are you storing plastics or higher-risk materials?
  • Does your layout impact sprinkler clearance or flue space?
  • Is this a large installation or a major layout change?

If you answered no to all of these, your project will likely never go through a formal permit process.

If you answered yes to one or more, it doesn’t mean you automatically need a permit, but it does mean your project is more likely to get a closer look.


How to Check Your Situation

You don’t need to overcomplicate it. If your storage height is approaching 12 feet, if you’re installing new racking, or if your layout affects fire protection, a quick call to your local fire department or building department can usually give you clarity.


So I have Determined I Need a Permit, What is Involved?

If your project does fall into a category that requires review, the process is usually straightforward, but it does involve a few key steps.

1. Layout Submission
You’ll provide a scaled layout (generally a CAD drawing) showing rack configuration, heights, aisle spacing, and building layout.

2. Product & Storage Details
You’ll need to define what you’re storing, how it’s packaged, and how high it’s stored. Fire code requirements are based on commodity type and storage height — not just the rack itself.

3. Fire Protection Review
This is typically the most important step. The review focuses on sprinkler compatibility, flue spacing, clearances, and overall layout.

4. Engineering (If Required)
Some projects require stamped drawings, anchoring details, or load information depending on size and height.

5. Plan Review & Approval
Your local fire or building department reviews the submission and may approve it or request adjustments.

6. Installation & Inspection
Once approved, the system is installed and may be inspected to confirm it matches the approved plan.

→ NOTE: Remember, most standard installations never go through this process… they simply don’t trigger these conditions.


FAQ: Pallet Racking Permits in Ohio

Do you need a permit for pallet racking in Ohio?
Most of the time, no. Standard installations typically do not go through a formal permit process. However, certain storage conditions may lead to review.

What is high-piled storage?
Storage of combustible materials where the top of storage exceeds about 12 feet.

Why do some areas seem stricter than others?
The code is the same statewide, but enforcement varies. Areas with more warehouse activity tend to review projects more closely.

Do I need a permit if my racking is under 12 feet?
Usually not, although other factors like product type and sprinkler interaction can still matter.

Who decides if a permit is required?
Your local authority having jurisdiction, typically the fire marshal or building department.


Need Help Figuring It Out?

If you’re not sure where your project falls, we can help. Send us your layout and we’ll tell you whether it’s likely to trigger review… before it becomes a problem.

If you’re still in the planning phase, we can design your system to align with fire code requirements and avoid surprises.

We’ve been installing pallet racking across Ohio for more than 31 years. If something needs attention, we’ll tell you. If it doesn’t, we’ll let you know also.


Final Takeaway…

In real-world practice, most pallet racking installations in Ohio move forward without a formal permit process.

The fire code comes into play when storage height, materials, and layout increase fire risk, and those are the situations where a project is more likely to be reviewed.

Do You Need a Permit for Pallet Racking in Ohio? The Real Answer. Read More »

universal fit Flared channel wire decking for pallet racking

Universal Fit Flared Wire Mesh Decking for Pallet Racking

universal fit Flared channel wire decking for pallet racking

Not every pallet rack beam is designed for standard step channel decks. When beams do not have the traditional beam step, flared wire mesh decking is often the best solution. Built as a universal fit option, this style of decking rests on top of the beam rather than inside the step, making it ideal for structural rack, box beams, and older pallet racking systems.

For warehouses upgrading existing storage, flared wire mesh decking can improve safety, product support, and day to day usability without replacing the entire rack system.


universal fit Flared channel wire decking for pallet rack

What Is Flared Wire Mesh Decking?

Flared wire mesh decking uses welded steel support channels underneath the wire deck surface. Instead of straight channel ends that drop into a beam step, the channel ends are flared outward so they sit securely on top of the beam.

That design allows the deck to fit a wider range of beam profiles, which is why it is commonly referred to as a universal fit wire deck. It is especially useful in facilities with mixed rack styles or older systems where stepped beams are not present.


Where It Is Used?

Flared wire mesh decking is commonly found on structural pallet rack, box beam systems, flat top beams, and older teardrop rack that does not include a step. If standard decking does not seat properly on the beam, flared decking is usually the right alternative.

Because many warehouses expand over time with different brands and generations of rack, universal fit decking can simplify replacement and future additions.


Waterfall Front Design

Most flared wire mesh decks still use a waterfall front edge, meaning the wire mesh wraps over the front beam. This helps keep the deck aligned while giving the rack level a clean finished appearance.

The result is a deck that combines broad beam compatibility with the familiar look and performance of standard waterfall decking.


universal fit Flared channel wire decking for pallet racking with hole for tek screw

Capacity, Safety and Strength

Most standard flared wire mesh decks use three welded support channels and are commonly rated for around 2,500 pounds under evenly distributed loads. Higher capacities are available depending on deck size, wire gauge, and support channel configuration.

Many flared decks are available with pre-punched tabs for fastening the deck to the beam. This creates a more secure installation and can help reduce movement during pallet loading and unloading.

Choosing the right deck should always be based on rack dimensions, beam spacing, and the weight of the product being stored.


Cost and Availability

In many cases, flared wire mesh decking is priced similarly to standard channel decking. The main difference is availability. Standard decks in common sizes are often stocked, while flared decks are more commonly ordered based on rack dimensions and application needs.

That makes accurate measurements important before ordering replacement or new decks.


Optional Features…

Galvanized finishes are also available where corrosion resistance is important, such as coolers, freezers, humid facilities, wash down areas, and food storage environments.


Why Warehouses Choose Flared Decking?

Warehouses often choose flared wire mesh decking because it works across multiple beam styles, supports cartons and split pallets more effectively, improves sprinkler penetration, and increases visibility through rack levels. It also helps reduce dust buildup compared to solid shelving and can often be added to older rack systems without major modifications.


Need Flared Wire Mesh Decking?

If your pallet racking beams do not accept standard step channel decks, flared wire mesh decking may be the right fit. Midwest Material Handling can help identify your beam style, confirm deck sizing, and supply the right wire decking for your storage application.


FAQ’s

What is a flared channel wire deck?

A flared channel wire deck is a wire mesh pallet rack deck with support channels that flare outward at the ends and rest on top of the beam instead of inside a stepped beam. It is commonly used on structural, box beam, and older rack systems.

Is flared wire mesh decking considered universal fit decking?

Yes. Because it fits many beam styles without requiring a beam step, flared wire mesh decking is commonly considered a universal fit wire deck.

Does flared wire mesh decking cost more than standard decking?

In many cases, pricing is similar to standard channel decking. The biggest difference is that flared decks are often ordered in rather than stocked in common sizes.

Can flared wire decking be used on structural pallet rack?

Yes. It is one of the most common wire decking options used on structural pallet rack systems.

Can flared wire mesh decks be galvanized?

Yes. Galvanized options are available for cooler, freezer, wash down, humid, and corrosion-prone environments.

How do I know what size wire deck I need?

Measure the beam length, rack depth, and beam style. Capacity requirements should also be confirmed before ordering.

Universal Fit Flared Wire Mesh Decking for Pallet Racking Read More »

Dock Leveler shipping image

Dock Leveler Is Down? Easy Repairs You Can Do Yourself

Dock Leveler Hold Down

Dock Leveler Is Down? Easy Repairs You Can Do Yourself

When a mechanical dock leveler stops working properly, many facilities assume they need an expensive service call or a complete replacement. In many cases, neither is necessary. Some of the most common dock leveler problems can be fixed in-house with affordable replacement parts, basic tools, and a skilled maintenance technician. Main springs, hold downs, lip components, hinge pins, and related hardware are all repairable on many units. If you need help identifying the correct components, visit our dedicated Dock Leveler Parts page.

We are experts at identifying dock leveler parts from virtually all manufacturers. If you need help finding the correct replacement part, complete our Part Request Form and send us your information. We can quickly match the proper part number, provide pricing, and offer shipping options, including overnight and second day air service when downtime matters.

There are two basic types of dock levelers: mechanical dock levelers and electric-hydraulic dock levelers. This article covers mechanical dock levelers only. Mechanical units use springs, linkage, and hold down systems to operate. Electric-hydraulic dock levelers use motors, pumps, cylinders, and controls, which require a different repair approach.


Why Many Dock Levelers Can Be Repaired

Mechanical dock levelers are relatively simple in their design. Unlike powered systems with motors and electronics, they rely on springs, linkage, and mechanical components. That means many common failures involve individual parts that can be replaced without replacing the entire unit.

For facilities with an experienced maintenance technician, repairing the dock leveler in-house can reduce downtime, avoid emergency service costs, extend equipment life, and restore operation faster.


edge-o-dock (EOD) replacement parts Main Spring for dock leveler

How a Mechanical Dock Leveler Works

Mechanical dock levelers operate through two opposite functions.

Main Springs Raise the Deck.

The deck rises through stored energy from the main spring assembly. When the hold down is released, spring tension lifts the leveler deck upward so the lip can extend onto the trailer.

Hold Downs Keep the Deck in the Stored Position.

The hold down performs the opposite job. It keeps the dock leveler safely in the down position until the operator activates the release.

One component lifts. The other restrains.

Common Hold Down Styles:

Depending on the manufacturer and age of the leveler, hold down systems may use ratchet arms, cable release systems, or other proprietary mechanical designs. The design may vary, but the function remains the same.


Safety First Before Any Repair!

Before replacing any dock leveler part, the unit must be safely secured. The deck is heavy and can move unexpectedly if it is not properly blocked.

Use the maintenance strut or heavy blocking, confirm the deck cannot shift, mark the dock position out of service, and place safety cones or warning devices above the door. Keep forklifts, trailers, and pedestrians away until repairs are complete.

Properly securing the leveler is the most important step in the entire repair.


Easy Repair #1: Replace a Main Spring

Main springs commonly crack when worn. Even one failed spring can affect operation. For example, if a mechanical dock leveler has four springs and one spring is cracked, the leveler may no longer rise correctly.

Common symptoms include poor lifting, slow movement, uneven operation, excessive effort to operate, or visible cracks in the spring coil.

How to Replace It:

Secure the dock leveler and block the deck safely.

Pul bar or paddle for rite-hite dock leveler main spring replacement

  1. Relieve spring tension at the paddle by loosening the adjustment nut.
  2. Remove the old spring from the paddle and mounting points.
  3. Install the new spring in the same position as the original.
  4. Re-apply tension and adjust for proper lifting force.
  5. Cycle the leveler several times and confirm smooth operation.

Hold Down for mechanical dock levelers

Easy Repair #2: Replace a Hold Down

If the deck will not stay down, will not release properly, or works inconsistently, the hold down may be worn or damaged. This repair is a bit more involved than a main spring replacement, but it can still be completed with care and patience by an experienced maintenance technician.

How to Replace a Ratchet-Style Hold Down

If your dock leveler uses a ratchet bar and pawl system, worn hold down parts can often be replaced without replacing the entire leveler. Proper deck support and alignment are important during this repair.

How to Replace It:

  1. Secure the deck completely before touching the mechanism.
  2. Disconnect the pull chain from the release mechanism.
  3. Remove the clip ring or cotter pin from the top of the ratchet bar.
  4. Remove the top pin and lower the ratchet bar.
  5. Remove the lower mounting pin and take out the old hold down assembly.
  6. Position the new assembly and secure the lower pin.
  7. Reconnect the ratchet bar to the deck and install the upper pin.
  8. Reconnect the release chain.
  9. Test the pawl engagement and release function.

*Important Note:

If the pawl does not engage the ratchet bar correctly or the assembly is not aligned vertically, the dock leveler may fail to hold or may float during use.


blue giant cable style hold down KOP, entire assembly.

How to Replace a Cable-Style Hold Down

Cable-style hold downs use an enclosed box with an internal wound cable system. These units can be replaced, but extra care is required because stored cable tension may be present inside the housing.

How to Replace It:

  1. Secure the dock leveler and block the deck safely.
  2. Disconnect the release chain.
  3. Remove the cable clamp connecting the hold down cable to the float spring.
  4. Route the cable free from the rollers.
  5. Remove the lower retaining pin and lift out the old hold down box.
  6. Install the new hold down box in the same mounting position.
  7. Route the new cable through the rollers and float spring correctly.
  8. Apply proper cable tension and tighten the clamp securely.
  9. Trim excess cable if needed.
  10. Test the hold down for proper storage and release operation.

*Safety Warning:

Cable-style hold downs may contain significant internal wound cable tension. We generally do not recommend non-professionals open or rebuild the hold down box itself.


Easy Repair #3: Fix Lip Components

The lip assembly is the front plate that rests on the trailer during loading and unloading. It also contains replaceable wear parts that commonly fail over time.

Many mechanical dock levelers use a lip kick out spring to help extend the lip during operation. A small hydraulic cylinder commonly pulls the lip back into its keepers when the leveler returns to the stored position. If either part fails, the lip may not extend correctly or may not store properly.

Common lip repairs include kick out springs, return cylinders, hinge pins, and worn linkage hardware.


What About Lip Hinge Pins?

Lip hinge pins can be one of the more difficult repairs because rust, wear, alignment issues, and limited access can make removal challenging. However, with patience, proper tools, and mechanical skill, they can often be replaced successfully.

We supply lip hinge pins for many major manufacturers. Contact us for pricing and availability.


Replacement Parts Cost Less Than Downtime

Most dock leveler replacement parts are inexpensive compared to the cost of emergency service calls, shipping delays, lost productivity, or replacing the entire dock leveler. Replacing one failed component often restores normal operation quickly and economically.


Need Help Identifying the Right Part?

We help customers identify dock leveler replacement parts every day, including older units with worn tags or missing model information.

Send us the manufacturer name, model number, serial number if available, dock size, and photos of the leveler or damaged part. Complete our Part Request Form and we will help identify the correct replacement part quickly and provide pricing right away.


Dock Leveler shipping image

Fast Shipping Available

When your dock leveler is down, time matters. Overnight and second day air shipping are available and commonly used for urgent dock leveler parts orders.

Dock Leveler Is Down? Easy Repairs You Can Do Yourself Read More »

pallet rack for storage furnished for penn state universities music recital hall

Pallet Racking Storage for Penn State U. Music Recital Hall

pallet rack for storage furnished for penn state universities music recital hall          pallet rack for storage furnished for penn state universities music recital hall         pallet rack for storage furnished for penn state universities music recital hall

Not every pallet racking project happens in a warehouse. Some of the most interesting storage projects take place behind the scenes in buildings built for performance, education, and creativity. We were contacted by a large interior construction contractor in western Pennsylvania that was helping complete storage areas for Penn State University’s new recital hall project. They needed dependable pallet racking systems for stage equipment and instrument storage, tucked away from public view but essential to the day to day operation of the facility.

Penn State’s recital hall was developed as a modern performance venue created to support students, faculty, and visiting performers. While the audience experiences the architecture, acoustics, and stage design, a great deal happens behind the scenes. Organized storage plays an important role in keeping instruments, cases, stage materials, and support equipment protected, organized, and ready when needed.

pallet rack for storage furnished for penn state universities music recital hall

Storage Built for a Specialized Space

The photo above is a physical mock-up the architect created of the proposed space. The storage area that used this pallet rack is located behind the seating area and is not shown. For the first phase of the project, we supplied pallet racking that included:

  • 12 foot high x 42 inch deep uprights (green)
  • 8 foot long beams (orange)
  • Wire decking for multiple shelf levels

It was a surprisingly significant amount of pallet rack for what looked like a relatively small storage area. That is often the case when a facility needs to maximize every square foot. By using vertical storage space, the customer created organized capacity without increasing the footprint of the room.

The pallet racking system was designed to support storage for stage items, instrument cases, audio equipment, risers, maintenance materials, and other assets that needed to stay secure while remaining easy to access.

Wire decking added another important benefit by creating stable shelf surfaces for items that would not normally sit directly on pallet rack beams. This made the system more practical for storing cases, boxed materials, and irregularly sized equipment often found in performance environments.

Follow Up Order with Custom Gray Finish

After the initial phase, the contractor returned with an additional order for another storage area. This time, the project required a different configuration and a custom color finish. We supplied:

  • 8 foot high uprights
  • 8 foot long beams
  • Custom gray finish to meet project requirements

This follow up order highlights an important point. Pallet racking is not limited to standard warehouse colors or industrial settings. In universities, commercial interiors, and specialty facilities, appearance can matter just as much as function depending on the location.

More Than Just Warehouse Storage

Projects like this show how versatile pallet racking systems can be. While pallet racking is commonly used in distribution centers and warehouses, it also solves storage challenges in theaters, schools, maintenance departments, archives, and performance venues.

When designed correctly, pallet rack creates durable, organized storage in spaces most people would never expect.

We Ship Pallet Racking Nationwide!

Although many of our projects are throughout Ohio, we also supply pallet rack, wire decking, and storage systems for customers across the United States. Contractors, universities, manufacturers, and commercial facilities often need dependable pallet racking delivered directly to jobsite’s outside our home market, and we are equipped to help with those projects.

Whether the need is standard pallet rack, custom configurations, or accessories like wire decks, we provide practical storage solutions for facilities nationwide.

Need Storage Rack for a Unique Project?

We regularly supply contractors, businesses, schools, and institutions with practical storage systems for projects outside the typical warehouse environment. If you have a unique application or need help planning a storage area, we would be glad to help.

Pallet Racking Storage for Penn State U. Music Recital Hall Read More »

cheap, chinese made pallet rack upright hit by forklift

Pallet Rack Protection: Why Better Racking and Post Protectors Matter

cheap, chinese made pallet rack upright hit by forklift

Warehouse pallet racking systems can fail for real-world reasons, and this is a perfect example. This actually happened and this is a real photo… we took it after the damage occurred and we got the call. The pallet rack uprights shown were hit hard enough to twist and fail. In this case, there were likely two factors in play: a rack system that was not ideal for the application and the absence of post protectors at a vulnerable impact point.

Many warehouse accidents are blamed only on forklift operators, but that misses the bigger picture. Busy aisles, tight turns, limited visibility, congestion, and production pressure all increase the chance of contact. The best prevention strategy combines trained operators, properly specified pallet racking, protective guards, and routine inspections.


Why Pallet Rack Upright Quality Matters

Pallet rack uprights carry vertical loads and help stabilize the entire storage system. When upright columns are built lighter than needed or are not the best fit for the application, they may be more vulnerable to damage in demanding environments.

The racking shown in this photo was manufactured overseas and assembled in the United States after arrival. As you can see, the vertical and horizontal cross braces are not attached directly to the upright columns. Instead, they are bolted to welded tabs located on the inside of each column.

Even damage that appears minor can create larger issues over time, including unsafe storage, lost productivity, and expensive repairs or replacement.


Lowest Price Is Not Always Lowest Cost

Warehouse racking is a structural system, not just shelving. Differences in steel thickness, column design, bracing, connections, and tested capacity can affect long-term durability.

A lower upfront price can become more expensive later if the system is damaged easily, difficult to expand, or costly to replace after an incident. Before buying pallet racking, it is worth reviewing capacity requirements, forklift traffic, future expansion plans, replacement part availability, and overall layout efficiency.


Why Post Protectors Matter

Even high-quality pallet rack systems benefit from impact protection. Accidents can happen in any active warehouse, which is why front columns and aisle ends should be protected wherever possible.

Post and Column Protectors

Post protectors mount around the base of pallet rack uprights to absorb incidental contact and reduce direct damage to the column. They are one of the most effective and affordable ways to protect vulnerable rack legs.

End of Aisle Guards

End of aisle guards create a barrier in front of exposed rack frames where turning forklifts and pallet jacks commonly make contact.

Guard Rails and Guide Rails

Steel rails help separate travel lanes from storage rows and reduce the chance of direct rack impact in high traffic areas.

Bollards and Safety Barriers

Fixed bollards and barriers are ideal near doors, dock areas, and building columns where vehicle movement is constant.


Where Protection Matters Most

The highest risk areas are usually front columns at floor level, aisle ends, tight turning zones, forklift intersections, and traffic lanes near shipping doors or dock openings.


Protection Costs Less Than Emergency Replacement

Many facilities wait until damage happens before adding guards or upgrading their racking. In most cases, prevention costs far less than replacing uprights, unloading inventory, blocking aisles, and dealing with lost productivity.

The better investment is choosing the right rack system from the start and protecting it properly.


What to Do If a Rack Upright Is Hit

If pallet racking has been damaged, remove loads if necessary, secure the area, inspect nearby components, and replace damaged parts promptly. Once repairs are complete, adding post protectors or guards can help prevent repeat incidents.


Protect Your Warehouse Racking Before Damage Happens

Midwest Material Handling helps facilities choose the right pallet racking for their application and supplies rack protection products including post protectors, column guards, end of aisle guards, and other warehouse safety solutions.

If you need help evaluating existing racking or improving protection in high traffic areas, our team can help.


Frequently Asked Questions

Are small dents in pallet rack uprights a problem?

Yes. Even minor dents or bends should be evaluated because they can affect capacity and worsen over time.

Do quality pallet rack uprights really make a difference?

Yes. Properly specified uprights can provide better durability, capacity, and long-term performance for the application.

Where should post protectors be installed first?

Start with front columns, aisle ends, and any area with frequent forklift traffic.

Can damaged uprights be repaired?

They can but it depends on the severity and rack type. In many cases, replacement is the safest and least expensive option.

Pallet Rack Protection: Why Better Racking and Post Protectors Matter Read More »

Keystone style pallet rack inside fire-damaged storage space with collapsed roof debris

We Don’t Get Calls Like This Every Day: What a Major Fire Revealed About Keystone Style Pallet Rack

Burned warehouse interior showing damaged pallet rack beams and debris after fire Fire-damaged storage building with pallet rack still standing after major fire in Dublin Ohio

We don’t get calls like this every day. A long time customer in Dublin, Ohio recently reached out after a major fire destroyed a small storage space. The building was heavily damaged, the contents were gone, and debris covered the area. But inside the burned structure, one thing was still standing and clearly recognizable… the pallet rack.

That project became a real-world reminder of how durable industrial storage systems can be. In this case, part of the system included Keystone style pallet rack, a long-trusted rack design used in warehouses and commercial storage facilities for decades.

If you are planning a new storage layout, replacing damaged rack, or looking for dependable used components, visit our Pallet Rack Systems in Ohio page to learn more about available options.

When Everything Else Was Gone, the Rack Was Still There

After the fire, roofing materials had collapsed, wood components were destroyed, and the storage area was filled with smoke damage and debris. Yet much of the pallet rack remained standing. That does not mean every component was reusable. Fire exposure can affect steel, anchors, and beam connections. Any fire-damaged pallet rack should always be inspected before being placed back into service. Still, the fact that the rack system remained after such severe conditions says a lot about how pallet racking is built.

Burned warehouse interior showing damaged pallet rack beams and debris after fire

How Extreme Heat Can Affect Steel

Some of the beams showed visible deflection after the fire due to the extreme heat. That is an important detail because it reflects the intensity of the fire more than a weakness in the beam itself. Steel changes when exposed to high temperatures. It can expand, soften, and deform under severe fire conditions. That is why damaged rack components should be replaced or professionally evaluated before reuse.

Even with that beam deflection, the pallet rack was still one of the only structures left standing inside the building.

What Is Keystone Style Pallet Rack?

Keystone style pallet rack is an older roll-formed pallet rack system that was widely used in warehouses, back rooms, and industrial storage areas for many years. While it is no longer one of the most commonly installed new rack styles today (teardrop style is), we still see Keystone rack regularly in the field.

Many facilities still use Keystone systems and contact us when they need used Keystone pallet rack, additions, or replacement beams for Keystone rack. We also help customers match existing pallet rack when expanding older layouts.

Keystone style pallet rack remains valuable because it offers:

  • Adjustable beam elevations
  • Strong load capacity when properly configured
  • Expandable layouts for changing storage needs
  • Replacement options through used components or factory sourcing
  • Efficient use of warehouse floor space

For facilities already using this style, Keystone pallet rack can still be a practical and cost-effective solution.

Why Pallet Rack Is Built for Tough Environments

Warehouse pallet rack is designed for demanding industrial use. Unlike light-duty shelving, pallet rack systems are built to handle palletized loads, forklift traffic, and changing inventory needs. Key advantages include:

  • Structural Steel Construction: Frames and beams are manufactured for strength and long service life.
  • Modular Components: Individual beams, frames, decking, and accessories can often be replaced as needed.
  • Flexible Layouts: Systems can be reconfigured, expanded, or relocated as operations change.
  • Long-Term Value: Well-maintained pallet rack often remains in service for many years

Long-Term Value

Well-maintained pallet rack often remains in service for many years. This fire was an extreme example, but it highlighted something many warehouse operators already know: pallet rack is built tougher than most people realize.

Need Keystone Style Pallet Rack in Ohio?

Midwest Material Handling supplies new and used pallet rack systems in Ohio, including help with matching existing systems, adding bays, replacing damaged components, and planning complete warehouse layouts. Whether you need one row of rack or a full facility setup, we can help you find the right solution.

Why Choose Midwest Material Handling?

Businesses across Ohio rely on us for practical storage solutions and honest guidance.

We help with:

  • New and used pallet rack
  • Keystone style pallet rack matching
  • Warehouse storage layouts
  • Rack additions and replacements
  • Component sourcing
  • Local and regional project support

Get Help With Pallet Rack Solutions

Need to match existing rack, replace damaged components, or plan a better storage layout? Contact Midwest Material Handling today for help with Keystone style pallet rack and warehouse racking systems in Ohio.

Frequently Asked Questions

Can pallet rack survive a fire?

Pallet rack may remain standing after a fire, but every system exposed to heat should be inspected before reuse.

Why did the beams bend in the fire?

Extreme heat can cause steel to expand, soften, and deflect. That usually reflects fire conditions rather than normal load performance.

Is Keystone style pallet rack still available?

Yes. Many facilities still use Keystone style systems, and compatible components may be available depending on size and project needs.

Do you sell used pallet rack in Ohio?

Yes. We supply both new and used keystone and teardrop style pallet rack systems based on availability and application requirements.

We Don’t Get Calls Like This Every Day: What a Major Fire Revealed About Keystone Style Pallet Rack Read More »

Post protector fail, how not to protect your pallet rack upright

Pallet Rack Post Protection in Ohio: The $50 Upgrade Most Warehouses Overlook

In warehouses across Ohio, pallet rack damage usually doesn’t come from one big incident, it comes from small, repeated impacts that weren’t properly addressed. We spend a lot of time in customer facilities for inspections, quotes, and layout work, and we see things like this all the time. Not because people don’t care, but because quick fixes get put in place and never revisited.

Post protector fail, how not to protect your pallet rack upright

This one, though, was well… creative, to say the least!

Someone had clearly decided the rack upright needed protection. That part is right. But instead of installing a proper pallet rack post protector, they strapped a yellow pipe to the column with zip ties and called it good. From a distance, it almost looks like pallet rack protection. Up close, it’s not anchored, not secure, and not actually protecting the part of the upright that takes the impact. It’s a common situation in working warehouses, good intention, wrong solution.


Why Pallet Rack Post Protection Matters

Pallet rack systems are designed to handle vertical load, not repeated impact from forklifts and pallet jacks. That’s why pallet rack post protectors and column protectors are such an important part of warehouse racking safety. Most damage happens low, right at the base of the upright. That’s the area that takes the hit in tight aisles and high-traffic zones. Once that section is compromised, it can affect the strength of the entire rack bay. Without proper pallet rack protection in place, even small impacts can lead to bigger issues over time, bent uprights, reduced load capacity, and eventually repair or replacement.


The Part Most Warehouses Overlook

What stands out in situations like this is how avoidable it is. Pallet rack post protectors are one of the least expensive safety upgrades you can make in a warehouse. Most steel post protectors cost $50 or less, install quickly, and are designed specifically for this exact problem. Instead, we often see makeshift solutions, pipes, wood blocks, or guards that aren’t anchored, giving the appearance of protection without actually doing the job. That’s where problems start.


What Proper Post Protectors Actually Do

A real pallet rack post protector is built to take impact and protect the upright behind it. It anchors directly to the floor, sits tight to the column, and absorbs or deflects contact before it reaches the rack itself. That’s the key difference, without anchoring, there’s nothing stopping the force from transferring into the upright.

Most facilities use either a 12-inch or 18-inch post protector depending on the application. The 18-inch height is the most common because it lines up with typical forklift impact zones. For operations with mixed rack systems or multiple upright sizes, universal post protectors are a practical option. They fit a range of columns and only require two anchor bolts, which makes installation fast and consistent across the facility.

In seismic areas, properly anchored pallet rack protection becomes even more important. At that point, you’re not just preventing day-to-day damage, you’re supporting the overall stability of the rack system.


Warehouse Racking Safety Starts at Ground Level

It’s easy to focus on beams, decking, and load capacity when thinking about pallet racking. But most real-world damage starts at the floor. That’s why pallet rack column protection plays such a critical role in warehouse safety. It protects the most vulnerable part of the system and helps prevent small impacts from turning into structural problems.

In busy Ohio warehouses, where forklift traffic is constant, this is one of the simplest ways to extend the life of your racking and avoid unnecessary repairs.


Final Thought…

We see a lot of creativity out in the field, and there’s nothing wrong with trying to solve problems with what you have. But pallet rack protection isn’t an area where improvising pays off. When a proven solution exists and costs less than $50, it makes more sense to install something that’s actually designed to do the job.


Get the Right Pallet Rack Protection in Place

Midwest Material Handling supplies pallet rack post protectors and column protectors throughout Ohio, including standard 12-inch and 18-inch options, universal post protectors with simple two-bolt installation, and solutions designed for seismic environments.

If you’re looking to improve pallet rack safety or prevent damage in your facility, we can help you choose the right protection without overcomplicating it.


Frequently Asked Questions About Pallet Rack Post Protectors

What is a pallet rack post protector?

A pallet rack post protector is a steel guard that anchors to the floor and protects the base of a rack upright from forklift impact. It helps prevent damage to the most vulnerable part of the pallet racking system.


How much do pallet rack post protectors cost?

Many pallet rack post protectors cost $50 or less, making them one of the most affordable and effective warehouse safety upgrades available.


What size post protector do I need?

The most common sizes are 12-inch, 18-inch and 24-inch heights. An 18-inch post protector is the post common and is typically used in active forklift areas because it covers the main impact zone, while 12-inch options work in lighter-duty or tighter spaces.


Are universal post protectors worth it?

Yes. Universal post protectors are a practical option for facilities with different rack types. They fit a range of upright sizes and only require two anchor bolts, making them quick and easy to install. The are designed with Interlake-Mecalux Bolted Uprights in mind.


Do I need post protectors in a low-traffic warehouse?

Even in lower-traffic environments, pallet rack protection is important. Most rack damage comes from small, repeated impacts over time, not major collisions.


Are post protectors required in seismic areas?

While requirements vary, properly anchored pallet rack protection is especially important in seismic zones. It helps improve the stability of the rack system and adds an extra layer of safety.

Pallet Rack Post Protection in Ohio: The $50 Upgrade Most Warehouses Overlook Read More »

pipe stop option for cantilever racking

Pipe Stops for Cantilever Racking-Improve Lumber Storage Safety

removable pipe stops for cantilever rack       removable pipe stops for cantilever racking

If you’ve spent any time around lumber storage or long material racks, you’ve probably seen the same thing play out. Everything looks fine at first, but over time material starts creeping toward the end of the arm.

It doesn’t take much. A slightly off-center load, a little settling, or just repeated handling can shift things more than you expect. Before long, you’ve got boards or bundles sitting right at the edge.

That’s exactly why pipe stops for cantilever racking are used so often. They’re simple, relatively inexpensive, and they solve a problem that shows up in just about every real-world setup.


What Are Pipe Stops for Cantilever Racking?

Pipe stops are vertical steel posts that mount at the end of a cantilever rack arm. In most cases, they attach using a field-installable, bolt-on flange, which means you can add them to an existing system without modifying the rack itself.

Once they’re in place, they do one job. They stop material from moving past the end of the arm.

Some people call them pipe stops, others call them arm stops or safety stops. Either way, the goal is the same—keep the product where it’s supposed to be.


Why Material Movement Becomes a Problem

Cantilever racks are built for long materials, but a lot of what gets stored on them isn’t perfectly stable.

Lumber shifts. Pipe rolls. Bundles settle. Even when everything is loaded correctly, materials don’t just sit there forever. Forklift placement is not always perfect, and over time small movements add up. That’s when you start to see product hanging over the edge of the arm, or worse, ending up on the ground.

Pipe stops are a simple way to get ahead of that instead of reacting to it.


Why You See Them Everywhere in Lumber Storage

https://www.dcgraves.com/v/vspfiles/assets/images/Cant-lumber2.jpg
If you walk through a lumber storage area, you’ll notice pipe stops pretty quickly. There’s a reason they show up so often in that environment.

Lumber isn’t always uniform. Lengths vary, stacks aren’t perfect, and things settle over time. Without something stopping it, material naturally works its way outward.

Adding a pipe stop gives you a defined end point. It keeps stacks from creeping, makes loads easier to manage, and reduces the chances of material falling off the rack. It also just makes the whole system feel more controlled. And just as important, it’s not an expensive upgrade. That’s a big reason why so many operations use them.


Field Installable Makes This an Easy Upgrade

This is where pipe stops really stand out. Because they use a field-installable flange, you’re not locked into making this decision upfront when the rack is first installed. You can add them later, exactly where you need them. In many cases, if you know the original manufacturer of your cantilever rack, pipe stops can be added after the fact and matched to your existing system without any issue.

Installation is straightforward. The flange bolts onto the end of the arm and the pipe stop drops into place. There’s no cutting, no welding, and no major disruption to your operation. That flexibility is what makes this such a practical upgrade. You can start with a basic setup and add stops later as your needs change or as you start to see how your material behaves over time.


When Pipe Stops Make Sense

Not every setup needs them, but there are some clear situations where they’re worth adding. If you’re storing round materials like pipe or conduit, loose lumber that isn’t banded tightly, or anything with mixed lengths, you’re already dealing with movement. The same goes for operations where material gets handled frequently throughout the day.

In those cases, pipe stops are less of a nice-to-have and more of a practical improvement.


Keeping It Simple vs. Overthinking It

There are other ways to control material on cantilever racks, but most of them either add cost or require ongoing effort.

You can strap loads, but that takes time every time. You can build more containment into the system, but that can limit flexibility and increase cost. Or you can do nothing and deal with the occasional issue when it happens. Pipe stops sit in a good middle ground. They’re simple, permanent, and they don’t interfere with how the rack is used.


How This Fits Into Your Cantilever Rack Setup

Pipe stops are technically an accessory, but they have a real impact on how your system works day to day.

When you’re looking at a cantilever setup, it’s really part of a larger warehouse racking system, and small upgrades like this can make a big difference. It’s about how the material behaves once it’s on the rack. How it sits, how it shifts, and how easy it is to handle safely. Small additions like this tend to make a bigger difference than people expect.


Need a Second Set of Eyes?

Every operation is a little different. The type of material, how often it moves, and how it’s handled all play a role in what makes sense.

If you’re seeing material creep toward the edge of your rack arms, pipe stops are usually one of the first things to look at. They’re simple, cost-effective, and because they can be added after the fact, they don’t require a major system change.

If you want help thinking through your setup, Midwest Material Handling can walk through it with you and help you figure out what actually makes sense.


FAQ: Pipe Stops for Cantilever Racking

Do they take up usable space?
A little, but most people find the added control is worth it.

Can they be added to existing racks?
Yes. In most cases they are designed for field installation, and if the original manufacturer is known, matching components is usually straightforward.

Do they require welding or modification?
No. Most designs use a bolt-on flange, so installation is simple.

Do you need them on every level?
It depends on what you’re storing. Usually just where material is more likely to move.


Final Thought…

Not every improvement needs to be complicated or expensive.

Pipe stops for cantilever racking are a straightforward solution to a very common problem. They’re easy to install, relatively inexpensive, and flexible enough to be added after the fact when needed.

If you’ve ever seen material slowly work its way toward the edge of an arm, you already know why they’re worth considering.

Pipe Stops for Cantilever Racking-Improve Lumber Storage Safety Read More »

Redirack pallet rack beams and uprights during warehouse installation in Ohio

Even After 31 Years, Identifying Some Pallet Racking Still Stumps Us

Redirack pallet rack beams and uprights during warehouse installation in Ohio      Close-up of Redirack pallet rack beam connectors and uprights from Canadian rack system

After 31 years in business, we’ve seen just about every type of pallet racking you can imagine… new systems, used systems, discontinued brands, oddball layouts, and custom applications. But every so often, even we come across a style of pallet rack that makes us stop and take a second look. That happened recently on a new installation project in Ohio.

This pallet racking system was shipped down from Canada for us to install, and I’ll be honest, I had never seen this particular style in person before. After a closer look, we identified it as Redirack (North American Steel-North American Rack), a Canadian pallet racking system that is common north of the border but far less common in the United States.

One detail we noted during installation… the used racking did not currently include beam safety locks, which are commonly removed during disassembly. As an added safety measure, we plan to install a nut-and-bolt connection upgrade to help secure the beams to the uprights and provide additional peace of mind.

For a company that has spent more than three decades around warehouse storage systems, it was a reminder that there is always something new to learn in this industry.

How to identify Redirak pallet racking

A New Commissary Supporting U.S. Expansion

The project location is a brand-new Canadian commissary facility for a fast-growing Mediterranean and Middle Eastern restaurant franchise expanding into the United States. The brand currently operates several U.S. locations, with a much larger footprint of hundreds of stores in Canada. This new commissary is designed to support future U.S. growth while helping keep supply costs down for American franchisees through centralized purchasing, production, and distribution.

For those unfamiliar with the concept, the menu is centered around popular items such as:

  • Shawarma
  • Chicken and beef plates
  • Wraps and pita sandwiches
  • Rice bowls
  • Falafel
  • Fries and signature sauces

Their model combines quick service, bold flavors, and a strong focus on quality ingredients.

What Will Be Stored on the Rack?

This pallet rack system is being used for support materials and packaging products essential to daily operations, including:

  • Paper products
  • Wax paper for sandwiches
  • Cardboard cartons
  • Corrugated boxes
  • Other dry goods and packaging supplies

These items may not be the headline products, but they are critical to keeping a food production and distribution facility running efficiently.

Built to Support a Premium Meat Processing Operation

This facility is primarily a meatpacking and food preparation operation. The company places a strong emphasis on using only the highest-grade Halal meats and maintaining strict standards in sourcing, handling, and production. That means every part of the operation, from food prep to packaging storage to warehouse flow, needs to be organized, efficient, and dependable. Reliable pallet rack plays an important role in making that happen.

Why Experience Still Matters

Projects like this are a great example of why experience matters. Even when a system is unfamiliar, years in the field help you adapt quickly, install it correctly, and keep the project moving. After 31 years, we still enjoy seeing something new and helping customers get their operations ready for growth.

Get Help With Pallet Rack Installation in Ohio

Whether you have common teardrop rack, specialty imported systems, or a completely new warehouse project, Midwest Material Handling can help with layout planning, pallet rack installation, reconfiguration, and storage solutions. If you’re planning a warehouse expansion or need help with an existing system, contact our team today for practical guidance and competitive pricing.

FAQ’S

What is Redirack pallet rack?

Redirack and it’s parent company North American Steel is a Canadian pallet racking system commonly used in Canada. It uses proprietary-style beam connectors and is less common in the U.S. market.

Can you install pallet rack systems from other countries?

Yes. Experienced installers can assemble imported or uncommon rack systems when proper components and layout plans are provided.

What products are stored in commissary pallet rack systems?

Many commissary facilities store packaging materials, paper goods, boxes, dry goods, and support inventory used for daily foodservice operations.

Do you install pallet rack in food production facilities?

Yes. Pallet rack is commonly used in food production, distribution, and commissary environments for organized storage and efficient workflow. We install commonly in both freezers and dry storage locations.

How long does pallet rack installation take?

Many standard pallet racking installations can be completed within several days when materials are available, and we have local and regional installation crews available.

Even After 31 Years, Identifying Some Pallet Racking Still Stumps Us Read More »

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