In the hustle and bustle of managing warehouse inventory, how you use your space ultimately defines your efficiency and success. However, there are common areas in facilities that go unused for storage - like those in front of dock doors. Hence, over-dock door pallet racking is becoming increasingly popular.
These racks allow warehouse managers to utilize once-wasted space and transform it into new storage areas. Does that sound like something your warehouse could use? Then, keep reading for our ultimate guide to maximizing inventory storage with over dock door pallet racking.
What is Over Dock Door Pallet Racking?
Over-dock door pallet racking is just that: pallet racking is installed over the dock doors of warehouses to provide additional storage. The systems consist of sturdy racking structures installed directly over the doors, allowing businesses to store palletized goods in what would otherwise be wasted vertical space.
The pallet racks are primarily used for storing slow-moving inventory, seasonal items, or overflow stock. They keep these products easily accessible yet out of the way of daily operations.
So, what industries use them the most? This racking solution is particularly beneficial for sectors with high inventory turnover and limited floor space, such as e-commerce fulfillment centers, retail distribution warehouses, and manufacturing facilities.
Advantages of Over Dock Door Pallet Racking
Still trying to determine if over dock door pallet racking is the right move for your warehouse? Here’s a look at the top advantages of installing innovative storage systems to help you decide.
Space optimization: This system utilizes the often unused vertical space above loading dock doors, maximizing storage capacity without taking up valuable floor space.
Improved inventory organization: It provides additional storage for slow-moving or seasonal items, keeping them easily accessible yet out of the way of more frequently accessed inventory.
Enhanced efficiency: Storing items directly above the shipping and receiving area can reduce travel time and improve order fulfillment speed.
Cost-effective solution: It uses existing vertical space, potentially reducing the need for warehouse expansion or relocation.
Flexibility: The racking can often be customized to fit various door heights and widths, accommodating different warehouse layouts.
Increased safety: Designated storage areas for pallets can reduce clutter on the warehouse floor, minimize trip hazards, and improve overall safety.
Better use of dock areas: It allows the space near the doors to serve dual purposes - for loading/unloading and for storage.
Improved inventory visibility: Items stored in these racks are often easily visible from the floor, aiding inventory management.
Next, if you’re convinced that over-dock door racks could solve your warehouse’s storage problem, you’ll need to learn how to install them. We’ll cover the step-by-step process to complete our ultimate guide.
How to Install Over Dock Door Racks
Of course, in any operation, you don’t want to act hastily and throw up new racks, without a plan. To ensure the addition of over dock door racks goes smoothly and suits your operational strategies, here’s a step-by-step guide to installing the racks to consider first.
Step #1: Assessment
As we mentioned, it’s best to evaluate your warehouse’s structure and dock door areas first to ensure they’re viable for installing pallet racks over them. This will include measuring the available space above doors, determining weight capacity requirements, and selecting an appropriate racking system.
Step #2: Design
The next step is to create a detailed layout plan for installing your over dock pallet racks. This stage will include ensuring that the installation complies with local building codes and safety regulations and having a structural engineer review and approve the plans.
Rest assured, if this seems out of your scope, a warehouse design specialist like BMH can help support this step and others.
Step #3: Preparation
The next step is to prepare for installation by clearing the area, ensuring proper lighting and access for installation equipment, and marking the floor for the placement of uprights and anchor points.
Step #4: Support Installation
Then, it’s time to install the vertical uprights by securing them to the floor and possibly the ceiling, depending on your design. Once the vertical uprights are installed, the horizontal beams are next. To finish, install any necessary bracing for the structure's stability.
Step #5: Rack Installation
Now’s the time for the good part! The next step is to attach pallet support bars or decking. This will also include installing any necessary safety features like wire mesh decking or backstops and any additional components unique to your warehouse, such as pallet flow systems, etc.
Step #6: Safety
Safety’s always first, so the sixth step includes verifying that all connections and weight capacities are secure and met. This includes ensuring proper clearance for material handling equipment and installing safety signage indicating any weight limits or usage instructions.
Step #7: Testing
Before using the pallet racks on an operational day, conduct load testing to ensure structural integrity and accessibility of forklifts and other equipment.
Step #8: Final Inspection
Any new structure should always be inspected by a qualified professional before use and obtain any necessary certifications or approvals from code inspectors, etc.
Step #9: Employee Training
Another crucial step before using is training the warehouse staff on the proper use of over-dock door pallets and safety procedures to be mindful of. It also helps to provide documentation on weight limits and handling processes to employees.
Step #10: Maintenance
Last but certainly not least, you must establish a regular inspection and maintenance schedule within your operation’s standard operating procedures.
Of course, the best strategy for maximizing your warehouse storage space and efficiency is to call in the experts. A third-party warehouse design expert, like BMH, sees your warehouse and its processes with new eyes. This helps uncover new ways of working to become more efficient and new ways to configure your existing storage space to maximize its efficacy.
The Final Word: Over Dock Door Racks
Now that you know everything you need to know about over-dock door racks, the last thing you should do is install your own. To start, contact the leading warehouse storage and design professionals at BMH. BMH is one of the fastest-growing companies in the material handling space, having grown 732% year over year.
Grow just as quickly alongside BMH by streamlining the way your warehouse manages and stores inventory. Browse our entire inventory of warehouse supplies, shelving, and equipment, learn more with our collection of resources, or send us a message to begin custom-designing a warehouse that works for your business.
