Question 1

What types of warehouse equipment do you provide?

Accepted Answer

We offer a wide range of material handling equipment, including:

Rack systems (pallet racking, cantilever, push-back, and more)
Conveyors and automated storage systems (AS/RS)
Mezzanines and modular offices
Pallet jacks and lift tables
Safety products, including guardrails, netting, and barriers
And more

See our Products Page for more information.

Question 2

Can an AS/RS work with mixed pallet sizes and weights?

Accepted Answer

Yes. Modern automated storage and retrieval systems can be engineered to handle mixed pallet sizes and weight ranges. Warehouse Cubed designs AS/RS solutions with adjustable load-handling devices, dynamic weight sensing, and smart software rules so each pallet—light or heavy, short or tall—moves safely and efficiently through the same automated aisle.

Automated storage and retrieval systems (AS/RS) are engineered to accommodate a broad range of pallet footprints and load capacities.

Telescopic forks, variable-width shuttles, and crane grippers fitted with load cells automatically measure each inbound pallet, confirm that weight is within limits, and adjust their stroke so mixed sizes ride smoothly. The supervisory software then assigns a location based on real-time space, ensuring light pallets aren’t buried under heavier ones and oversized pallets are steered to deeper bays or wider channels.

Through Warehouse Cubed’s warehouse consulting services, our team evaluates your SKU mix, current racking, and future growth targets to specify the right configuration. We refine rail spacing, clearances, and cycle speeds during warehouse layout design, then tie the new equipment into your existing WMS or ERP as part of our material handling systems integration program. Optional checks—such as vision scanners that flag damaged pallets, dimensioning tunnels, and dynamic weight tracking—extend equipment life and keep OSHA limits in check.

The result is a flexible, high-density automation platform that combines multiple pallet standards in one footprint instead of separate rack zones. You gain faster put-away and retrieval, tighter inventory control, and a safer work environment while reducing labor and travel time. When peak season or a new product line arrives, the same AS/RS simply updates slotting rules—no costly re-racking required.

Question 3

Can you integrate cantilever racks for awkward items (pipe, lumber, furniture)?

Accepted Answer

Yes. Warehouse Cubed integrates heavy-duty cantilever racks into new or existing layouts to store awkward, oversized items like pipe, lumber, sheet goods, carpet rolls, or knock-down furniture. Our warehouse consulting services match arm lengths, capacities, and aisle widths to your loads so you get safe, space-saving storage that flows with forklifts and conveyors.

Cantilever racks are the go-to industrial storage solution for long, bulky, or irregular products that will not fit on standard pallet racking systems. During our warehouse optimization process, Warehouse Cubed’s engineers start with a detailed warehouse layout design and load analysis. We size uprights, bases, and adjustable arms for your exact bundle lengths, weights, and pick frequency, then position the towers so lift trucks have a clear, unobstructed face to deposit or remove pipe, lumber, mattresses, or ready-to-assemble furniture.

Because we are a full material handling systems integration partner, the cantilever rows are tied into adjacent selective racks, conveyor systems, or automated storage and retrieval systems (AS/RS) to create a seamless flow from receiving through order fulfillment. Options include structural or roll-formed steel, single- or double-sided configurations, galvanized finishes for outdoor yards, and removable arm stops to prevent product creep. If your operation must flex for new SKUs, we can combine cantilever with mobile base or bolt-together retrofit systems to reconfigure quickly.

Every installation is backed by our rack systems & repairs team and routine warehouse safety audits to keep capacities compliant and damage in check. The result is a safer, more organized facility that stores awkward items in 50 % less aisle space while boosting pick speed and protecting valuable inventory.

Question 4

Do I need wire decking or pallet supports, and how do I size them correctly?

Accepted Answer

Choose wire decking when you handle loose cartons, mixed SKUs, or need fire-code water flow and easy visual checks. Select pallet supports when every load rests on sound pallets and you only need extra bearing bars. In either case, match depth to rack frames, width to beam length, and meet the highest load rating with two supports per pallet.

Warehouse optimization starts with choosing the right shelf surface for your pallet racking systems. Wire mesh decking and welded-steel pallet supports both reinforce selective racks, yet they solve different problems. Wire decking creates a full shelf that catches broken pallets, allows sprinkler water flow, boosts airflow and visibility, and lets you store cartons or loose SKUs. Pallet supports are two or more bars that bridge the beams; they cost less and keep forklift access clear but only work when every load sits on a consistent, good-quality pallet.

Sizing steps:

1. Depth: match the rack frame depth—most U.S. racks are 36″, 42″ or 48″. A 42″ frame gets a 42″ deep wire deck or 42″ pallet support.

2. Width: wire decks are sold to fit clear beam length (e.g., two 46″ decks for a 96″ beam or three 46″ decks for a 144″ beam). Pallet supports should overhang the step or box beam about 1″ per side and be tek-screwed or clipped in place.

3. Capacity: choose a deck or support rating that meets or exceeds the heaviest uniformly distributed pallet load, typically 5,000–6,000 lb per pair of beams with pallet weights of 2,000 – 2,500 lbs; increase gauge or channel count for point loads.

4. Quantity: use at least two pallet supports per pallet position—add a third for heavy, weak, or nonstandard pallets.

Warehouse Cubed’s warehouse consulting services can verify load data, conduct rack inspections, and integrate the right material handling systems, supplying wire decking, flanged or hat-style pallet supports, and other industrial storage solutions that keep your operation safe, compliant, and ready for growth.

Question 5

Do you implement conveyors, sortation, or AS/RS that integrate with our WMS?

Accepted Answer

Yes. Warehouse Cubed designs, supplies, and installs conveyor systems, high-speed sortation, and automated storage and retrieval systems (AS/RS) that integrate seamlessly with your Warehouse Management System (WMS). Our veteran-owned team delivers turnkey material handling solutions, from concept and software interfacing to on-site commissioning and maintenance, for a unified, data-driven operation.

Warehouse Cubed’s warehouse automation solutions connect every moving part of your facility. Our engineers map your workflow, then create a warehouse layout design that blends conveyor systems, sortation equipment, and automated storage and retrieval systems (AS/RS) into one cohesive material handling system. We configure controls and middleware so each device exchanges real-time data with your WMS, giving you instant inventory visibility, automated routing, and exception handling without manual scanning.

Typical projects pair zone-route or tilt-tray sorters with belt or roller conveyors to speed order fulfillment, while shuttle-based AS/RS towers reclaim vertical space and feed goods directly to pick stations. Because we are a full-service material handling systems integration partner, you get one point of contact for equipment sizing, software logic, installation, and training. This holistic approach cuts implementation time, reduces integration risk, and ensures that reporting, wave planning, and replenishment rules inside your WMS work flawlessly with the physical hardware on the floor.

Whether you manage an e-commerce distribution center that ships thousands of parcels a day or a manufacturing warehouse that needs just-in-time part delivery, our conveyor, sortation, and AS/RS solutions boost throughput, lower labor costs, and provide the scalability to grow alongside your business.

Question 6

Do you offer pallet rack installation services, and what do you need to quote it?

Accepted Answer

Yes. Warehouse Cubed provides turnkey pallet rack installation nationwide. To give you an accurate quote we’ll ask for your facility address, clear height, floor‐slab rating, desired rack style and pallet count, product weights, a basic layout or CAD drawing, and a target timeline. A free phone consultation gathers these details quickly.

As part of our warehouse consulting services, Warehouse Cubed supplies, engineers, and installs pallet racking systems—from selective and push-back to drive-in and cantilever rack. Because every project is unique, our quoting checklist focuses on the information that drives cost, speed, and compliance. Send us the following information for the most accurate quote:

1. Facility facts: site address, square footage, clear ceiling height, concrete-slab thickness, sprinkler or seismic zone, and access hours.

2. Storage goals: pallet dimensions, average and maximum load weight, SKU mix, throughput targets, and growth plans.

3. Rack preferences: type, number of pallet positions, bay width and depth, beam levels, accessories, or whether you need guidance from our warehouse optimization specialists.

4. Drawings: a simple sketch, PDF floor plan, or existing CAD file lets our warehouse layout design team create a space-efficient model in hours.

5. Project timing: desired install window, shift schedules, and any shutdown constraints.

Once we receive these details our engineers prepare CAD layouts, load calculations, and a fixed-price proposal covering material, freight, professional installation, and optional pallet rack repair or ongoing maintenance. The result is a safer, denser, future-ready warehouse completed with minimal downtime.

Question 7

How do I choose the right used pallet rack uprights or frames?

Accepted Answer

Verify capacity, height, and hole pattern; inspect for damage or rust; and match load requirements before buying any used pallet rack upright or frame. Measure column depth, gauge, and beam connector style so components stay compatible. Warehouse Cubed’s used pallet rack equipment is always inspected and certified for safe reuse.

Pallet racking systems only perform safely when every upright is sized and rated for your application, even if it is a bargain on the secondary market. Begin with precise data: pallet size, load weight per level, lift-truck clearances, seismic zone, and overall clear height of the building. Match these numbers to the frame’s published capacity chart; if the tag is missing, Warehouse Cubed can calculate the load and label the frame correctly.

Next, confirm compatibility. Measure the column depth (usually 36–48 inches), gauge of steel, and the connector style—such as teardrop, keystone or structural bolted. Mixing brands that have similar punch patterns can lead to loose beam connections, so keep to one manufacturer or let our material handling systems integration team supply adapter clips.

Inspect condition. Reject frames that show twists, cracked welds, or more than 1/8-inch column deflection. Surface rust is cosmetic, but deep pitting, bent baseplates, or enlarged anchor holes reduce capacity. Our pallet rack repair kits restore minor forklift damage and bring uprights back to RMI compliance at a fraction of replacement cost.

Finally, think ahead. If future SKU growth or automation is likely, select frames tall enough for another beam level and anchor points that accept rack safety equipment. With Warehouse Cubed’s warehouse optimization experts, you can source vetted, refurbished frames from trusted brands, or design a hybrid system that blends used uprights with new beams—saving capital today while safeguarding productivity for years.

Question 8

How do you future-proof a warehouse for automation?

Accepted Answer

Future-proofing starts with a data-driven warehouse layout design that leaves clear expansion zones for conveyors, robotics, and automated storage and retrieval systems. Combine flexible pallet racking, mezzanines, and modular in-plant offices with a scalable WMS interface, robust power and network drops, and a proactive safety and maintenance plan so new automation can bolt on later.

Begin by auditing your current workflows and growth forecasts with experienced warehouse consulting services. A smart, future-ready plan spaces out high-density pallet racking, pick tunnels, and conveyor spurs so aisles, ceiling clearances, and column grids align with later installation of robotics or shuttle-based automated storage and retrieval systems (AS/RS). Design mezzanines and modular in-plant offices on bolt-together frames, giving you extra capacity now while keeping floor space open for future goods-to-person stations or sorter loops.

Next, integrate power, compressed air, and high-speed data drops along main travel lanes and at every rack bay. This “digital backbone” lets you add sensors, vision systems, or autonomous mobile robots without rewiring the facility. Tie each zone to a flexible warehouse management system and material handling equipment controls layer; open APIs allow new automation components to plug in as order profiles change.

Finally, protect uptime with scheduled pallet rack repair, safety guarding, and annual warehouse safety audits. A well-documented maintenance and permitting program keeps structures compliant, minimizes retrofit downtime, and safeguards employees as throughput rises. By combining scalable material handling systems integration, robust infrastructure, and continuous optimization, you build a distribution center that can adopt the next generation of supply chain automation on your timetable.

Question 9

Is teardrop pallet racking compatible across different brands?

Accepted Answer

Teardrop pallet racking systems are generally cross-compatible because most brands punch the same 2-inch-on-center teardrop pattern. Teardrop punches usually lock into other teardrop uprights, even from different manufacturers. Still, double-check tab fit, safety clips, and load ratings. Warehouse Cubed offers inspections and warehouse optimization guidance.

Warehouse Cubed often installs teardrop pallet racking systems because their teardrop-shaped punches sit 2 inches on center. This spacing creates a nearly universal joint between uprights and step beams.

In most cases you can mix beams and frames from major manufacturers. No drilling or adapters are needed.

Yet there are important caveats. Each brand’s tab shape, clip thickness, and locking pin style can vary. Small changes can weaken the joint or stop the safety clip from locking. Load charts are tested only with the maker’s own parts. If you mix brands, you take on the liability. In seismic or high-bay areas, inspectors may ask for an engineer’s letter that proves the mix is safe.

Our warehouse consulting services remove the guesswork. We perform on-site rack inspections, check column gauge, connector size, and safe load charts. We can source matching teardrop parts or build pallet rack repair kits for damaged beams. Pair these with a full warehouse safety audit, layout design, and broader warehouse optimization plan to keep your storage system OSHA and RMI compliant, ready for warehouse automation, and safe for your team.

Question 10

What is teardrop pallet racking and why is it so common?

Accepted Answer

Teardrop pallet racking is a selective rack whose uprights have tear-shaped slots; beams drop in tool-free on 2-inch centers so parts from most brands interchange. Because it installs fast, is widely stocked new and used, and reconfigures easily, it has become the default pallet-rack style across North America.

Teardrop pallet racking is the most common roll-formed selective rack in the United States. The upright frames are punched with upside-down teardrop slots on two-inch centers. Beams have tapered studs that drop in, lock automatically, and can be moved with no tools. Because nearly every major manufacturer—Interlake Mecalux, Unarco, and others—uses the same hole pattern, parts are interchangeable. You can explore options on our Pallet Rack Systems solutions page. That universal fit delivers three big advantages:

1. Lower cost of ownership – mix new, used, or refurbished components and source replacements fast.

2. Speedy installation and reconfiguration – boltless connections let your team or a Warehouse Cubed crew adjust beam levels in minutes.

3. Broad accessory support – wire decks, pallet supports, safety bars, and pick-zone add-ons all snap into the same slots.

When you partner with Warehouse Cubed, our warehouse consulting services start with warehouse layout design and warehouse optimization modeling. We supply high-quality teardrop frames, beams, and decking, integrate them with conveyor or automated storage and retrieval systems as part of complete material handling systems integration, and back everything with rack safety audits and pallet rack repair kits. The result is a space-saving, code-ready storage solution that scales with your operation and supports future warehouse automation solutions.

Question 11

What measurements do I need to match teardrop beams to existing uprights?

Accepted Answer

To match new teardrop beams to your existing uprights, measure six things: 1) vertical hole pitch and slot shape, 2) column depth and face width, 3) lug spacing on the original connectors, 4) clear inside-to-inside beam span, 5) beam face/step size, and 6) required shelf capacity rating.

Start by confirming the upright hole pattern—a quick warehouse optimization check. On most roll-formed “universal” or “teardrop” frames the slots repeat every 2.0 inches, but older rack sometimes use 3-inch or offset spacing. Place a tape against one column flange and note the center-to-center distance between three consecutive holes; this figure must match the vertical lug spacing on the replacement beam connector.

Next note the slot profile. A true teardrop opening has a ½-in. round top that narrows to roughly 3⁄8-in. in the neck. If the neck is wider or squared, you may be dealing with an Interlake New Style, Ridg-U-Rak “slotted,” or another proprietary pattern and the beam must come from that manufacturer.

Measure the column depth (front-to-back) and width (left-to-right across the face) so the connector plates seat flush without twisting. Then record:

Clear span between inside faces of opposing uprights—this is the beam length you will order.
Beam face height and step depth (for step beams) to hold wire decking or pallet supports.
Desired load capacity, because two beams working as a pair must support the shelf without exceeding either the beam or upright rating.

If any dimension is uncertain, Warehouse Cubed’s warehouse consulting services team can perform an on-site rack audit, match compatible pallet racking systems from Interlake Mecalux or Unarco, and integrate the beams into a broader material handling systems integration plan—complete with pallet rack repair, safety audits, and future-ready warehouse automation solutions.

Question 12

What pallet rack beam size (96” vs 144”) is most cost-effective?

Accepted Answer

For many facilities, 96-inch beams are the lowest-cost option because they use lighter steel and fit the standard two-pallet layout. A 144-inch beam can cut cost per pallet in long, light-load runs, but heavier steel and decking usually offset the savings.

In pallet racking systems, choosing the most cost-effective beam length comes down to the trade-off between component price and pallet density. In most projects we design, an eight-foot (96 in.) beam wins on installed cost because it fits two standard 40 x 48 in. pallets with 3–4 in. clearance; uses lighter roll-formed steel, so the beam and connectors are cheaper; pairs with standard 3 in. uprights, lowering frame price and freight; and keeps deflection within the L/180 rule without extra center supports.

A twelve-foot (144 in.) beam holds three pallets, letting you eliminate every third upright and add density. If each pallet is under about 2,500 lb, cost per pallet position can be reduced and you gain more pick faces. The catch: longer beams need deeper or thicker profiles, heavier uprights, and wire decking with extra crossbars. These costs may cancel or reduce the savings unless you have long, continuous runs.

Our warehouse consulting services model both options in a complete layout, considering load weight, SKU velocity, aisle width, and future growth. This insight powers broader warehouse optimization and material handling systems integration, ensuring your rack system balances price, safety, and throughput.

Whether you pick 96 or 144 in. beams, Warehouse Cubed supplies the right steel, handles installation, and provides ongoing rack inspections and repair to protect your investment.

Question 13

What should I look for when buying used uprights or used frames?

Accepted Answer

Check that used uprights or frames are straight, rust-free, and have intact bracing; verify the column depth, hole pattern, and steel gauge match your beams; confirm load capacity from the original manufacturer; and always have a qualified provider like Warehouse Cubed review any used materials before installation.

Used pallet-rack uprights (also called frames) can save money, but only if they are safe and compatible with your material-handling system.

1. Structural condition – Sight down each column for bowing, twists, cracked welds or missing horizontal/diagonal braces. Push-pin holes should be round, not elongated, and base plates must be firmly attached.

2. Capacity documentation – Ask for the original manufacturer’s data sheet that lists frame load ratings by unsupported height. Without it, you cannot prove OSHA or RMI compliance. Warehouse Cubed offers warehouse safety audits to verify capacities and supply stamped calculations when needed.

3. Compatibility – Measure depth, column face width and hole style (teardrop, keystone, structural bolt-up, etc.) to be sure the frames accept your existing beams and decking. Mixing styles reduces capacity and slows future warehouse optimization.

4. Future layout – Make sure the frames fit the clear height, seismic zone and lift-truck aisle design in your warehouse layout. Our warehouse consulting services can model new and refurbished racking in CAD so you know every position will work before you buy.

5. Hidden costs – Calculate cleaning, repainting, hardware, anchors and freight. Sometimes a refurbished frame or a quick rack-repair kit costs less than repeated downtime.

When you partner with Warehouse Cubed for pallet racking systems and material handling systems integration, we inspect, rate and recondition every used upright so you get a cost-effective, code-compliant storage solution you can trust.

Question 14

Which rack system is best for high-turn full pallets vs. deep reserve storage?

Accepted Answer

For high-turn, full-pallet picking, a single-deep selective rack (or pallet flow when FIFO is critical) delivers the fastest access and simplest slotting. For deep reserve or bulk SKUs, density matters more than speed, so drive-in or 2–6-deep push-back racks maximize cubic capacity while reducing aisle count.

High-velocity pallet positions demand immediate, one-touch accessibility. Warehouse Cubed typically recommends single-deep selective pallet racking for these SKUs because every location faces the aisle, letting lift-truck drivers grab or replenish product in seconds without shuffling other loads. If you ship dated goods and need strict first-in/first-out rotation, our engineered pallet flow lanes add gravity rollers to keep the oldest pallet at the pick face while preserving the same quick pick cycle. Both options pair well with narrow-aisle lift trucks to boost pick density without sacrificing speed.

Reserve or slow-moving inventory calls for the opposite approach: maximum storage density at the lowest cost per pallet. Drive-in/drive-thru and 2- to 6-deep push-back racks condense up to 65 % more pallets in the same footprint by eliminating most access aisles. Push-back delivers last-in/first-out access and higher selectivity than drive-in, while drive-in offers the absolute lowest cost per position for large runs of a single SKU. Our warehouse consulting services use CAD-based layout design and capacity calculations to determine the ideal mix of high-turn and deep-reserve zones, integrating conveyors, AS/RS, or other material handling systems as needed.

Whether you operate an e-commerce fulfillment center or a 3PL, Warehouse Cubed’s turnkey pallet racking systems, installation, and ongoing rack repair keep your operation safe, flexible, and future-ready.

Equipment