identify dock leveler parts from only a photo

How We Identify Dock Leveler Parts Without Serial Numbers

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.

How We Identify Dock Leveler Parts Without Serial Numbers Read More »

Edge of dock leveler with steel approach plate

Installing an Edge of Dock Leveler (EOD) on an Old Dock

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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.

Installing an Edge of Dock Leveler (EOD) on an Old Dock Read More »

wire partition system for secure server room with magnetic door lock

Secure Wire Partition Installation for an Ohio Server Hosting Facility

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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.

Secure Wire Partition Installation for an Ohio Server Hosting Facility Read More »

Pallet racking uprights, beams and wire decking

Ohio High School Creates Mock Warehouse to Train Future Forklift Operators

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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.

Ohio High School Creates Mock Warehouse to Train Future Forklift Operators Read More »

Vertical Bar Rack by Vestil Manufacturing

Vertical Bar Rack for Pipe, Conduit & Lumber Storage

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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.

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.

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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

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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.

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.

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 Is Down? Easy Repairs You Can Do Yourself

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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.

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.

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

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:

Secure the deck completely before touching the mechanism.
Disconnect the pull chain from the release mechanism.
Remove the clip ring or cotter pin from the top of the ratchet bar.
Remove the top pin and lower the ratchet bar.
Remove the lower mounting pin and take out the old hold down assembly.
Position the new assembly and secure the lower pin.
Reconnect the ratchet bar to the deck and install the upper pin.
Reconnect the release chain.
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.

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:

Secure the dock leveler and block the deck safely.
Disconnect the release chain.
Remove the cable clamp connecting the hold down cable to the float spring.
Route the cable free from the rollers.
Remove the lower retaining pin and lift out the old hold down box.
Install the new hold down box in the same mounting position.
Route the new cable through the rollers and float spring correctly.
Apply proper cable tension and tighten the clamp securely.
Trim excess cable if needed.
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.

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

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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.

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

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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 »