Pallet Rack-Galvanized vs. Standard Powder Coated… is it worth it?
We are often asked for recommendations on Pallet Rack or Cantilever Rack for outdoor use. The options are relatively simple… we sell full, hot dipped Galvanized Pallet Rack Uprights, Beams and Wire Decks. We also carry Cantilever Racking and all related accessories, fully suitable for outdoor use.
What is Galvanizing? Galvanizing is a proceed that takes raw, unpantied metal and is “hot dipped” into a molten zinc chemical bath mixture. This process, when dry makes the metal resistant to corrosion and rust. There are several different methods to galvanize (like electro-galvanizing) but hot dipping is, by far the most common. You likely see galvanizing in products designed for prolonged time spent outside or in hot/cold exterior climates. While not totally permanent, with care, a galvanized Pallet Rack Upright, Beam or Wire Deck can be rust and corrosion free for decades.
But is the additional cost worth it? That is difficult to answer. The average cost for galvanized Pallet Rack is generally 3-4 times the cost for standard Racking.
Why is it so expensive? Industrial Rack manufacturers do not galvanize themselves, they have to ship the Racking to a local galvanizer, where the process is performed. Once complete, the Racking is then shipped back to the manufacturer, where it is prepped for shipment. All of these “steps” contribute to the overall added cost.
Due primarily to cost, we do not sell a lot of galvanized Pallet Racking. We sell to several large, big box home improvement retailers. They purchase it primarily for their outdoor products and landscape items. We often say that you could purchase standard, powder coated Rack, which you know, in time will rust (if left outdoors) 3 to 4 times over for the same cost of one order of galvanized Pallet Rack. Remember, this chemically treated Racking gets damaged just as easily as standard Rack, the galvanizing does nothing to improve that! Additionally, the galvanizing process adds weeks onto lead times.
We visited a Customer facility last week as they wanted to add additional Pallet Racking sections to their current layout. This customer is a large national wholesale retailer and a longtime customer of ours. As we toured the facility, we noticed Steel Post Protectors that we installed several years ago absolutely doing their job! The whole concept behind the Post Protector is to protect the Upright columns from forklift or fork truck damage. We want the Post Protector to absorb the contact, protecting the Upright columns from structural damage. As you can see here, this is exactly what is occurring.
We are often asked… “what is the best method to protect my Pallet Rack Upright columns from damage”? Fortunately, the answer is also the least expensive method, the $50 Post Protectors. These simple protective devices simply require 4-5 concrete wedge anchors to install. These units come in a range of different heights, 12″H, 18″H and 24″H.
Contact the experts at Midwest Material Handling, LLC for information on a range of high-quality containers are used in laundries, hospitals, textile mills, garment plants, and through out the hospitality industry. Founded in 1913, Dandux is THE leading manufacturer of quality canvas and fabric carts, baskets, hampers and trucks designed to increase your productivity and make your operation more efficient.
Styles include extra duty (sewn on liner), frame trucks (lace on liner), net and bag holder storing system, wood top shipping hampers, extra heavy postal specification trucks, and a variety of shapes and sizes to meet your needs. Available in plain white canvas or yellow glosstex, lace on liners available in six optional colors.
The quality of workmanship of our fabric hand truck starts without frame construction. We use high tensile spring steel electroweld to give additional strength and rigidity. Selected kiln-dried hardwood runners are attached to the steel frame. Heavy duty canvas or GLOSSTEX fabric ( in six standard stock colors ) is added to complete the rugged, cost effective basket or truck you demand.
Canvas Baskets & Trucks
We offer an extensive line of carvas basket, hampers and trucks. Styles include Extra Duty (sewn on liner), Frame Trucks (lace on liner), Net & Bag Holder sorting system, Wood Top Shipping Hampers, Extra Heavy Postal Specification Trucks and a variety of shapes and sizes to meet specific needs.
Skid Boxes
Skid Boxes feature interlocking legs for secure stacking. Available in a many sizes and styles (double or single wall). Easily fork truck liftable for transporting.
Poly Box Trucks
Box Trucks are the strongest unit of its type available. The unique Double Wall Flange provides superior strength when handling heavy loads. (Available in 12, 16, 18, 19 & 24 bu.)
Refuse Carts
Mobil Refuse Carts safely and conveniently transport materials to collection areas. Choose from three sizes 24, 32 and 64 gallon and three colors (gray, blue, green, gray standard colors).
Dividable Tote Boxes
Dividable Tote Boxes are the largest selection available. Choose from over 100 sizes for the one that best meets your needs. Selection consists of stackable or nestable styles.
Stack and Nest Totes
Stack & Nest Totes are available in an extensive selection of sizes. The 180 degree stacking feature allows for stacking when in use or nesting when stored.
Tilt Trucks
Tilt Trucks are ideal for collecting, moving and dumping materials. Available in six optional colors. Available sizes: 1/2, 1, 1 1/2, & 2 cubic yard capacities.
Palletubs
Palletubs are ideal for in plant or over the road transport. Features are: fork truck liftable, stackable on lids and nestable for return trip.
Poly Bulk Trucks
Poly Bulk Trucks are ideal for handling large loads. They are designed to handle large loads while maximizing space. Available in six colors (blue standard) and many different sizes.
Nesting Totes
Nesting Totes provide an efficient means for carrying an assortment of items. Choose from over 100 sizes and shapes to meet your needs. (Some sizes available with lids).
All of these items are proudly manufactured in the USA and are available for quick ship! Call us today.
Every so often, a project comes along that’s not only rewarding, but also a lot of fun to be part of. A few years back, a unique project with BrewDog Brewing in Canal Winchester, Ohio definitely fits that description! What started as a single, small Pallet Rack order turned into a large, multi-stage pallet racking installation that supported both their production needs and their customer-facing space.
Before the project even began, we initially coordinated with BrewDog’s team headquartered in Scotland, which added another unique layer of communication and planning. Their team was fantastic to work with and helped set the foundation for the early stages of the installation before everything shifted to the Canal Winchester location.
If you’ve ever been inside BrewDog’s facility, you know it’s a busy place… constantly moving product, constantly growing, and always looking for ways to operate more efficiently. That meant they needed storage solutions that could keep up with their pace, but also give them the flexibility to expand as their needs changed. Instead of ordering everything at once, BrewDog purchased their pallet rack in stages, adding on as new areas were built out and as the brewery continued to scale.
A Project That Grew Alongside the Brewery
The first phase focused on back-of-house storage. We installed heavy-duty pallet racking to help them organize incoming ingredients, packaged beer and brewery equipment. With the amount of product they move in and out each week, improving the flow of materials was a high priority. The new racking immediately made a difference by giving them more vertical storage and reducing clutter on the warehouse floor.
As the project continued, BrewDog expanded their front-of-house retail space. They wanted racking solutions that looked clean and professional but were sturdy enough to hold cases, merch, and seasonal items. We matched the design to their existing layout so everything looked intentional, not just functional.
Each new stage added another layer to the overall footprint, and before long, the job evolved into a very large installation. By the final phase, the system we had built together supported a wide range of operational needs, from production to retail.
Teamwork, Flexibility and a Great Partner
One of the most enjoyable parts of this project was the collaboration. BrewDog knew what they needed, and we helped them figure out the safest and most efficient way to achieve it. Timing was important, and since they were purchasing racking as needed, we made sure each phase was scheduled and installed in a way that didn’t slow down their daily operations.
It’s always rewarding to step back at the end of a project like this and see how much the space has transformed, especially knowing the system will support BrewDog’s growth for years to come.
A Look Ahead…
Whether it’s a small add-on or a large multi-stage installation like this one, we take pride in helping businesses build storage systems that actually work for the way they operate. BrewDog was a great partner throughout the process, and we’re proud to have played a small role in their continued success in Canal Winchester.
If your business is expanding or you’re considering updating your storage layout, allow the team of experts at Midwest Material Handling, LLC to help you explore the options!
From a buyer’s perspective this has always been a difficult and often times confusing decision. Let’s first briefly discuss the advantages of purchasing USED Pallet Racking.
Advantages
Obviously, the overriding thought when considering purchasing USED Pallet Racks is cost. A secondary, but equally important benefit is the USED equipment is on-site and available immediately, saving time and freight costs.
Now for the reality… Many buyers wrongly think that purchasing USED Pallet Racking and Wire Decking is similar to that of purchasing a used car (for example), that there is a 50% or 60% savings over the cost of NEW. Unfortunately, this is rarely the case.
Let’s discuss why…
When we are contacted by a seller who has USED equipment available, the vast majority of the time, the racking is still standing and needs to be disassembled. Once we send a crew into disassemble the Rack, we then need to stack, band and prep it for shipment. Once complete, the USED Pallet Rack needs to be shipped, via flatbed to our location. Due to its size and length, USED Rack/Wire Decks are generally stored outside, allowing the powder coated finish to begin rusting and oxidizing. One item of note, many buyers have little regard for the discoloration or aesthetic appearance of the USED Racking, they simply want it to work! Add all of that up and the NEW vs. USED savings is somewhere in the vicinity of 15%-20%.
Damage
One other very important consideration… historically, we have rarely sold USED Pallet Rack Uprights as they generally have some sort of column damage (probably 4 out of 5 Uprights sustain damage from forklift forks or skids) usually located at the lower 12”-24” of the two front Upright columns. * NOTE: If there is ever a ding or dent in an Upright… BUYER BEWARE! The structural integrity of the Upright has been compromised and the Upright should be discarded. There are disreputable companies and social media sellers out there that will sell them, but we won’t (and you should not buy them)!
Condition
While we stock and sell a significant amount of USED equipment (primarily Pallet Rack and Wire Mesh Decks), the quality and condition of the USED equipment we sell is exceptional. We only sell USED material that has an overall condition rating of 8-9 out of 10, we do not sell anything with any lower condition rating. All of our USED Racking has a condition rating applied to it at arrival and is always furnished and noted on our proposals. Of course, pictures are always available when the Racking cannot be viewed in person or we are shipping it out of area. You can always trust our condition ratings to be accurate and thorough.
Modern manufacturing techniques have improved to the point that, many times, purchasing NEW can actually be less expensive than buying USED. Even more so, the same holds true for USED Pallet Rack purchased at auctions or auction settings, but that’s a conversation for another day. Additionally, another great geographical advantage he have is the majority of our NEW Wire Mesh Deck Panels are manufactured (ITC Manufacturing) right here in Columbus, Ohio! Pick them up and save the freight!
Warehouse efficiency is often discussed in terms of automation, robotics, or complex software systems. While those technologies certainly play a role, one of the most important factors is much simpler: how the warehouse is physically organized.
The layout and design of storage racking systems determine how easily inventory moves through a facility. When storage is poorly planned, forklifts travel farther than necessary, aisles become congested, and valuable floor space is wasted. A well designed racking layout can dramatically increase storage capacity while making everyday operations faster and safer.
For many warehouses, improving efficiency does not require expanding the building. It simply requires making better use of the space that already exists.
Why Storage Layout Matters More Than Most People Think
Walk through any busy warehouse and you will notice that most of the activity revolves around moving pallets. Forklifts are constantly retrieving, storing, and repositioning inventory throughout the facility. If the storage layout is inefficient, every one of those movements takes longer than it should.
Even small improvements in storage design can make a noticeable difference. Shorter travel distances, clearer aisle access, and better organization all contribute to smoother operations.
Well planned racking systems also make inventory easier to manage. When pallet positions are clearly defined and easy to access, employees spend less time searching for products and more time moving orders out the door.
High Density Storage Is Becoming More Important
As inventory volumes increase and industrial real estate becomes more expensive, warehouses are looking for ways to store more product within the same footprint.
High density racking systems are one of the most effective solutions. These systems reduce the amount of aisle space required and allow pallets to be stored deeper within the rack structure.
Drive in rack systems allow forklifts to enter the rack structure and store pallets several positions deep. This approach works well when large quantities of the same product are being stored together.
Pushback racking uses a system of nested carts that allow pallets to be stored multiple positions deep while remaining accessible from the aisle. As pallets are removed, the remaining pallets roll forward into position.
Both systems allow warehouses to significantly increase pallet capacity compared to traditional single deep storage layouts.
Flexible Storage Systems Support Changing Inventory
Warehouse operations today are rarely static. Product lines change, inventory levels fluctuate, and order volumes shift throughout the year.
Adjustable racking systems help facilities adapt to those changes. Beam levels can be repositioned to accommodate different pallet heights, and sections of racking can be modified as storage needs evolve.
This flexibility allows warehouses to adjust their storage layout without major construction or facility expansion.
Technology Is Supporting Smarter Warehouse Operations
Modern warehouses are also benefiting from improved technology. Warehouse management systems provide real time visibility into inventory levels and product locations. Scanning systems reduce errors during receiving, picking, and shipping.
Some larger operations are also exploring robotics and automated picking systems to handle repetitive tasks more efficiently.
However, even the most advanced technology still depends on a well organized storage layout. When storage systems are designed properly, both employees and automated systems can work faster and more efficiently.
The Right Storage System Makes a Long Term Difference
Improving warehouse efficiency rarely comes from a single change. Instead, it usually comes from combining better storage systems, improved workflow design, and the right equipment.
A well planned racking layout can increase pallet capacity, reduce congestion, and improve overall productivity without expanding the building.
For a closer look at different warehouse racking configurations and storage options, visit our page covering warehouse pallet racking systems and storage solutions.
Cleveland, Ohio-We recently completed a pallet rack guarding project in Cleveland, Ohio for a manufacturing facility focused on improving warehouse safety. The safety manager reached out after identifying potential risks tied to pallets stored on upper rack levels. In a busy environment, loads shift, product gets bumped, and improperly positioned skids can create unnecessary hazards. The goal was simple. Protect employees and visitors working near the pallet racking system.
After reviewing the existing layout, we recommended a wire rack guarding solution from Husky Rack and Wire.
Why Pallet Rack Guarding Matters in Cleveland Warehouses
In many Cleveland facilities, pallet racks run alongside pedestrian walkways or active workstations. When that happens, added protection becomes important. Wire rack guards attach directly to the pallet rack upright columns and create a rigid barrier that helps prevent pallets or loose product from falling into aisle ways or work areas.
Unlike netting, wire panels provide consistent protection while still allowing light and visibility through the rack bays. Employees can clearly see stored inventory while gaining an added layer of safety.
For this facility, the rack guarding solution delivered:
• Added protection along active rack aisles • Improved safety near exposed workstations • Greater confidence during plant tours and visits • A stronger alternative to worn or torn netting
Product Details and Quick Ship Availability
The wire rack guards are available in several standard sizes and fit common beam lengths of 96 inch, 108 inch, 120 inch and 144 inch bays. Heights of 3 foot, 4 foot and 5 foot allow the guarding to match different rack openings.
Standard size panels can ship within 24 hours for orders totaling 2,500 pounds or less, making this a practical option when safety concerns need to be addressed quickly.
Panels ship crated to prevent freight damage, with one crating charge covering up to 23 panels.
When to Consider Rack Guarding
Facilities often explore pallet rack guarding in Cleveland when:
• Pedestrian traffic runs alongside rack systems • Workstations are positioned directly next to rack bays • Pallets have previously been pushed through rack levels • Stored product has caused wall damage • Existing safety netting is no longer adequate • The facility hosts regular visitors or plant tours
In these situations, adding wire rack guards is a straightforward way to reduce risk without changing the overall rack layout.
Supporting Safer Facilities in Cleveland, Ohio
Every warehouse operates differently, but safety concerns around pallet racking are common. In this Cleveland project, rack guarding provided a durable and effective upgrade that strengthened protection around existing storage systems.
We are often asked what the most effective way is to protect pallet rack uprights from forklift damage. The answer is actually pretty simple. One of the most reliable and affordable solutions is a steel pallet rack post protector.
Forklift traffic moving pallets in and out of rack bays can easily strike the front upright column. Even a small impact can bend the upright or weaken the rack structure over time. Installing a steel post protector creates a barrier between the forklift and the rack column.
Most pallet rack post protectors are 12 to 24 inches tall and are designed to fit around the front of standard rack uprights. Typical inside dimension widths range from about 4.5 inches to 8.5 inches depending on the rack manufacturer.
Post protectors are one of the least expensive yet most effective ways to protect pallet rack uprights from forklift damage.
Why Post Protectors Are Important?
Pallet racking represents a significant investment for most warehouses. When an upright column becomes damaged, the structural integrity of the rack system can be compromised and repairs can become expensive.
Steel post protectors act as a barrier positioned directly in front of the rack upright. When a forklift makes contact with the protector, the impact is absorbed by the guard rather than the rack column.
Because they are inexpensive and easy to install, post protectors have been used for decades in warehouses of every size. A single protector often costs less than fifty dollars, yet it can prevent serious damage to rack structures, stored product, and equipment.
Preventing Forklift Damage to Pallet Racks
Forklift impact is one of the most common causes of pallet rack damage in warehouses. Tight aisles, heavy loads, and fast paced operations increase the chances that a forklift may accidentally contact the rack structure.
When a forklift strikes a pallet rack upright directly, the force can bend the column or weaken the frame. Over time repeated impacts may reduce the load capacity of the rack system and create safety concerns.
Installing steel post protectors provides a simple way to reduce the risk of forklift damage. The protector absorbs the impact before the forklift reaches the upright column, helping preserve the structural integrity of the rack system.
How Post Protectors Are Installed
Most steel post protectors are anchored directly into the concrete floor in front of the pallet rack upright.
Installation is simple. The protector is positioned around the front of the column and secured to the concrete using concrete anchors. Most manufacturers require four or five anchors depending on the specific design.
A commonly used anchor is a half inch diameter concrete wedge anchor measuring approximately 3.75 to 4 inches in length. These anchors provide strong holding power and keep the protector firmly in place during impact.
Some installations may also use concrete screw anchors. These can reduce installation time, which becomes especially helpful when several hundred protectors are being installed throughout a warehouse.
Another option is a bolt on style protector that attaches directly to the rack column rather than the floor. These versions are available in both steel and heavy duty plastic.
Heavy Duty Steel Construction
Most pallet rack post protectors are manufactured from heavy gauge steel to withstand repeated impacts from forklifts and pallet jacks. Five gauge steel is commonly used because it provides excellent strength and durability.
The protectors are typically finished in a bright safety yellow paint or powder coated finish. This makes them highly visible to forklift operators and helps reduce accidental contact with the rack base.
This combination of strong steel construction and high visibility makes post protectors a simple but very effective way to improve warehouse safety.
Protecting Your Rack Investment
Even minor forklift contact can damage pallet rack uprights over time. Repeated impacts may weaken the rack frame and create safety risks for both stored product and warehouse personnel.
Installing pallet rack post protectors provides a simple and affordable solution to help prevent this type of damage. They help extend the life of rack systems while reducing maintenance costs and improving overall warehouse safety.
How tall should a pallet rack post protector be? Most facilities use protectors between 12 and 24 inches tall. This protects the lower portion of the rack upright where forklift impacts most commonly occur.
How are post protectors installed? Most steel post protectors are anchored directly to the concrete floor using wedge anchors or concrete screw anchors.
Are steel or plastic post protectors better? Steel protectors generally provide greater durability and impact resistance in heavy duty warehouse environments.
Are post protectors required for pallet racking? They are not always required, but they are strongly recommended in warehouses with frequent forklift traffic.
Midwest Material Handling developed the concept and layout for a large scale rack supported pick module system for a major international auto glass manufacturer in Mobile, Alabama. Working in collaboration with engineering support from Interlake Mecalux, the system was structurally engineered and then installed by our team to create a high density storage solution capable of organizing and picking more than 9,100 SKUs within a limited warehouse footprint.
The success of this design led to the system being duplicated at additional service center locations throughout the United States, creating a standardized storage model for regional operations.
Project Scope and Requirements
The facility handled a wide range of windshield and specialty glass products with varying dimensions and weights. SKU count exceeded 9,100 active items, and available floor space did not allow for horizontal expansion.
Key requirements included:
• High density SKU organization • Efficient hand picking access • Structural support for a mezzanine platform • Long clear spans for oversized glass products • Scalable design for replication across multiple facilities
Traditional shelving would not provide sufficient structural capacity. A conventional pallet rack layout alone would not deliver the SKU density required for manual picking operations. The solution required an engineered integration of rack structure and wide span shelving.
System Engineering and Design Collaboration
Midwest Material Handling developed the initial layout concept, storage configuration and operational flow strategy for the pick module system. Interlake Mecalux provided structural engineering support to ensure load calculations, rack frame performance and mezzanine integration met required specifications.
The system was built around standard roll formed pallet rack uprights and beams that served as the primary structural framework. These rack frames supported a mezzanine platform, creating a second level of storage without increasing building footprint.
Above the mezzanine level, wide span shelving was installed to store lighter but oversized truck windows and specialty glass components. The extended beam spans allowed clean SKU separation and open hand access while supporting required load capacity.
Because the system was engineered as a repeatable model, it could be adapted and duplicated across additional service center locations with consistent structural and operational performance.
For more information on this storage solution, visit our Wide Span Shelving in Ohio page.
Installation and Execution
Midwest Material Handling managed on site installation, structural coordination and full system integration. Due to the size and complexity of the project, installation required nearly one month of coordinated field work to complete.
Careful attention was given to:
• Structural load distribution across rack frames • Mezzanine attachment and alignment • Beam span selection for oversized product storage • Multi level structural consistency • Safe and efficient vertical access
Completing a project of this scale within an operational industrial facility required disciplined sequencing, crew coordination and strict adherence to engineered specifications.
Operational Results
The completed pick module system delivered measurable improvements in storage density and picking efficiency. By building vertically rather than expanding outward, the facility significantly increased usable storage capacity within the existing footprint.
Results included:
• Organized storage for more than 9,100 SKUs • Improved vertical space utilization • Reduced picker travel distance • Clear separation of oversized and specialty products • A scalable system design implemented at additional service centers nationwide
By combining pallet rack structural support with wide span shelving storage levels, the facility achieved high density organization while maintaining safe and efficient hand access.
Engineered Pick Module Systems
Pick modules are engineered storage systems built around rack supported platforms and multi level shelving. They are commonly used in high SKU environments where picking accuracy, accessibility and vertical utilization directly impact operational performance.
Midwest Material Handling develops layout concepts, collaborates with manufacturer engineering teams and installs integrated rack supported pick module systems tailored to inventory profile, SKU count and facility constraints.
To learn more about rack supported storage systems, visit our Selective Pallet Rack Ohio page.
We were contacted by the Department of Defense and the U.S. Navy to furnish and install heavy duty wire lockers for a Naval Special Operations (SEAL) unit. This project required secure, durable military lockers designed to withstand constant daily use in a demanding environment. For organizations that need dependable steel lockers, employee lockers, facility lockers, athletic lockers, public safety lockers, or specialized storage systems, we supply solutions built for long term performance with professional installation services throughout Ohio.
We designed, supplied, and installed a TA-50 locker system manufactured by WireCrafters. These rugged storage lockers are specifically engineered for military applications where security, ventilation, and strength are critical. The completed locker installation became an important part of the modernization and upgrade of the Naval Operations Center.
All of our locker systems are proudly made in the United States!
