A warehouse racking system for pipes, timber and other long materials must control three risks at the same time: unstable loads, difficult access and inefficient use of floor space. The right design begins with accurate material data, continues with a safe layout and suitable cantilever rack, and ends with disciplined installation and operation.
This guide explains the complete design process in practical steps. It is intended for warehouse managers, purchasing teams, engineers, contractors and operators who need to store steel pipes, plastic pipes, timber, aluminum profiles, furniture boards, tubes, bars, conduits and other oversized products.
Do not select a rack before identifying exactly what the warehouse will store. Different products create different load, access and safety requirements.
Pipes and tubes: Round products can roll, so they need arm lips, stops, cradles, separators or other anti-rolling measures.
Timber and wooden boards: Timber can vary significantly in weight, moisture content, length and surface condition. Bundled timber may need wider arms and stronger support.
Steel sections and bars: Steel is dense and may create very high point loads. The rack must be rated for the actual bundle weight, not only the average product weight.
Aluminum profiles and plastic lengths: These products may be light but flexible. They need enough support points to prevent bending.
Mixed lengths: Different product lengths may require adjustable arms, different rack bays or a combination of single-sided and double-sided racks.
Finished products and raw materials: Finished goods may require better appearance protection, while raw materials may prioritize fast picking and high capacity.
Measure the longest, widest, highest and heaviest storage unit that the rack must support. Use the actual bundle or pallet dimensions when products are stored in bundles.
Minimum and maximum product length.
Product diameter or cross-section.
Bundle width and height.
Weight per item and weight per bundle.
Number of bundles stored at each level.
Required quantity of each stock keeping unit.
Product rigidity and deflection risk.
Whether the material is loose, strapped, boxed or palletized.
Whether the material can be handled by hand, forklift, crane or a combination of methods.
For a basic load estimate, calculate the load on one rack level as follows:
Level load = number of stored bundles x weight of one bundle
For a cantilever rack, the total load on the complete upright should include every loaded arm level:
Upright load = load on level 1 + load on level 2 + load on level 3 and so on
Use a safety margin approved by the rack manufacturer or structural engineer. Never design the system using an estimated weight that is lower than the actual operating load.
The building determines how much rack can be installed and how safely the rack can operate. A good plan considers the complete working environment, not only the available floor area.
Measure the total length, width and clear height of the storage area.
Locate columns, walls, doors, loading docks and fire exits.
Record the position of sprinklers, lights, ventilation ducts and electrical panels.
Check the condition, thickness and levelness of the concrete floor.
Confirm the floor load capacity with the building owner or structural engineer.
Identify vehicle routes, pedestrian routes and emergency access areas.
Measure the turning radius and operating height of forklifts or reach trucks.
Check local fire, seismic, building and occupational safety requirements.
Identify areas exposed to rain, humidity, chemicals, impact or temperature changes.
Purchasing teams usually need to balance price, capacity, safety, delivery time and future flexibility. A low initial price is not necessarily the lowest total cost if the rack cannot store the required products or must be replaced after expansion.
Capacity certainty: The supplier should provide clear load ratings for uprights, arms, bases and complete rack bays.
Space utilization: The design should improve usable cubic capacity without creating unsafe handling conditions.
Product flexibility: Adjustable arm levels are valuable when stock lengths and bundle sizes change frequently.
Safety documentation: Buyers should request drawings, load tables, installation instructions and inspection guidance.
Installation responsibility: Confirm whether the quotation includes delivery, unloading, installation, anchoring and commissioning.
Spare parts: Arm pins, safety stops, braces, anchors and replacement components should be available after installation.
Future expansion: The system should allow additional bays or accessories where the building and floor capacity permit.
Total cost of ownership: Compare rack cost, installation cost, maintenance, handling time and expected service life.
Cantilever racks are designed with vertical columns, horizontal arms and a stable base. Since the front of the rack is open, operators can load and unload long materials without placing them through a conventional beam frame.
This configuration is suitable for pipes, timber, steel sections, profiles, boards, tubes and other products that are longer than standard pallets.
Open front access for forklifts and manual picking.
Adjustable arm levels for different product heights.
Efficient storage of long and irregular products.
Easy visual identification of stock.
Good separation between different product sizes.
Single-sided configurations for wall storage.
Double-sided configurations for central warehouse aisles.
Optional decking for boards, boxes and smaller items.
Choose the configuration according to the position of the rack and the required access direction.
Single-sided cantilever rack: Place it against a wall or at the edge of the warehouse. The arms project toward one operating aisle.
Double-sided cantilever rack: Place it in the center of the warehouse. The upright is shared by arms on both sides, increasing storage capacity in the same floor area.
Mobile cantilever rack: Use only when the required density justifies the additional engineering, controls and floor requirements.
Outdoor cantilever rack: Specify weather-resistant coatings, drainage details and protection against corrosion when racks are exposed to the environment.
A purchasing specification should describe the rack in measurable terms. Avoid vague descriptions such as heavy duty or industrial grade without numbers.
Overall rack height.
Overall rack length.
Number of bays.
Distance between uprights.
Arm length.
Number of arm levels.
Vertical spacing between levels.
Rated load per arm.
Rated load per level.
Rated load per upright or complete bay.
Base length and base load rating.
Arm slope, if required for product retention.
Safety lips, end stops or dividers.
Steel grade and section dimensions.
Surface finish, such as powder coating or galvanized treatment.
Anchor type and quantity.
Required accessories and replacement parts.
The arm should support the material without creating excessive overhang. As a general design principle, the stored product should have enough support points to prevent sagging and should not extend so far beyond the arm that it becomes unstable.
For long and flexible products, use more rack levels or more support points rather than placing a very long product on only two supports. For heavy steel bundles, confirm the concentrated load at each contact point with the rack supplier.
Arm spacing should allow safe loading while minimizing wasted vertical space. Leave enough clearance for the forklift, lifting attachment, product deformation and operator visibility.
Divide the warehouse into clear functional zones before drawing the rack layout.
Receiving and inspection zone.
Temporary quarantine zone for damaged or unidentified products.
Fast-moving material zone.
Slow-moving or reserve stock zone.
Cutting, processing or kitting zone.
Finished goods staging zone.
Dispatch and loading zone.
Pedestrian and forklift travel zones.
Maintenance and spare parts zone.
Keep receiving and dispatch paths as direct as possible. Long products should not cross busy pedestrian areas or require repeated repositioning through narrow aisles.
Determine how many bundles or storage units must be held at each rack level. Use peak inventory rather than average inventory if the warehouse must handle seasonal demand.
List every product family.
Record the maximum quantity required for each family.
Group products with similar dimensions and handling methods.
Assign one or more rack positions to each group.
Add a reasonable allowance for growth, damaged stock and temporary overflow.
Check that the final design fits within the available floor and height limits.
Do not fill every available position if doing so prevents safe loading. A rack needs practical working clearance, and operators need room to identify, remove and return stock.
Aisle width must be based on the forklift model, attachment, load length and turning method. A pipe or timber bundle may extend beyond the forklift carriage, making the effective operating envelope wider than the vehicle itself.
Confirm the minimum aisle recommendation from the equipment manufacturer.
Include the full load length and any side overhang.
Allow clearance for turning and alignment with the rack arms.
Separate forklift lanes from pedestrian walkways where possible.
Use physical barriers, guardrails or marked exclusion zones near high-traffic areas.
Keep emergency exits, fire equipment and electrical panels unobstructed.
Store the heaviest bundles at the lowest practical level. This reduces the center of gravity of the rack and limits the risk of dropping a heavy load from height.
Place frequently picked products near the dispatch or processing area, provided that the location does not create congestion. Reserve upper levels for lighter or slower-moving products when the rack design and handling equipment permit it.
Every rack, bay, arm level and product position should have a readable location code. A simple system can combine aisle, rack, bay and level information.
For example, a location code may use the format A03-R02-B04-L03, meaning aisle 3, rack 2, bay 4 and level 3. Use durable labels that remain visible from the operating aisle.
Use large labels at both ends of each rack row.
Use product labels that show size, material, quantity and weight.
Mark maximum bundle quantity where overloading is possible.
Use a warehouse management system or location list for stock control.
Review labels after every layout change.
Prepare the following tools and documents before installation begins.
Site measurement tape or laser distance meter.
Floor level and concrete inspection tools.
Warehouse layout drawing or CAD software.
Product dimension and weight records.
Forklift specification sheet.
Rack supplier load tables and assembly drawings.
Building floor load information.
Risk assessment and method statement.
Personal protective equipment requirements.
Inventory list and location coding plan.
The exact tools depend on the rack design and anchor specification. Confirm the tool list with the supplier before delivery.
Torque wrench with the required torque range.
Impact wrench or socket set approved for the fasteners.
Drill and bits suitable for the concrete anchor type.
Spirit level or laser level.
Measuring tape and chalk line.
Plumb line or alignment laser.
Socket and open-end wrenches.
Rubber mallet.
Shims approved for leveling the base.
Temporary bracing and installation supports.
Forklift, crane or lifting equipment suitable for the components.
Barriers, warning signs and exclusion-zone equipment.
Safety helmet, safety shoes, gloves, eye protection and high-visibility clothing.
The installation team should have the approved rack drawings and operating instructions at the work location. The documents should identify the rated capacity, anchor requirements, component arrangement and inspection method.
Rack assembly drawing.
Foundation or anchor plan.
Maximum load per arm and per level.
Maximum total load per upright or bay.
Permitted arm spacing and adjustment positions.
Required bracing arrangement.
Forklift operating rules.
Emergency response procedure.
Inspection checklist.
Compare the delivered components with the approved drawings and purchase order before moving them into the warehouse.
Check the number of uprights, bases, arms, braces, pins and anchors.
Inspect steel members for bending, cracks, coating damage or missing parts.
Separate damaged components and record them immediately.
Confirm that the installation area is clear of stock and unauthorized personnel.
Mark the work zone with barriers and warning signs.
Use the approved layout drawing to mark the centerline of every upright, base and aisle. Check the dimensions from at least two reference points so that small measurement errors do not accumulate across the warehouse.
Mark the front and rear edges of every rack row.
Mark each bay centerline.
Mark anchor hole positions according to the base drawing.
Mark aisle boundaries and pedestrian walkways.
Check clearances from walls, doors, columns and fire equipment.
A cantilever rack must stand on a stable, level foundation. Do not compensate for a seriously uneven or damaged floor by using improvised materials under the base.
Measure floor levelness along the full rack row.
Check for cracks, weak concrete, expansion joints and drainage channels.
Confirm that anchor holes will not be placed in unsuitable areas.
Repair or isolate defective floor sections according to engineering advice.
Use approved leveling shims only where the rack design permits them.
Place each base at the marked position and temporarily secure it. The base must be aligned with the rack row and must provide the designed resistance against overturning.
Check the base length and orientation.
Align the base with the aisle and neighboring bases.
Confirm that base plates sit fully on the floor or approved shims.
Do not omit base braces, tie members or other specified components.
Raise the uprights using suitable lifting equipment and install the horizontal and diagonal braces shown on the drawings. Keep the structure temporarily braced until all permanent connections are complete.
Lift the upright using approved lifting points.
Position it into the base connection.
Install the required bolts or connection hardware.
Connect horizontal braces at the specified levels.
Connect diagonal braces in the specified pattern.
Check that the upright is plumb in both directions.
Repeat the process for the remaining uprights.
Measure the bay spacing before final tightening.
Install the arms only after the uprights and bracing are stable. Arm position must match the approved design and the expected material dimensions.
Identify the correct arm length and capacity for each position.
Insert each arm into the upright connection at the specified level.
Install safety pins, locking bolts or other retention devices.
Check that every arm is fully engaged and cannot lift out during handling.
Confirm that left and right arms are installed at matching levels.
Install end stops, lips, dividers or cradles where required.
Check for visible deformation or damage.
Anchoring is a critical part of the system. Use the anchor type, diameter, embedment depth and quantity specified by the supplier or structural engineer.
Recheck rack alignment and plumbness before drilling.
Drill holes to the specified diameter and depth.
Remove dust and loose material from each hole.
Install the approved anchors according to the anchor manufacturer's instructions.
Tighten each anchor to the specified torque.
Record the installation results if required by the site procedure.
Recheck alignment after anchoring.
Never replace specified anchors with ordinary bolts or install fewer anchors than shown on the drawings. If the floor condition differs from the design assumption, stop the installation and obtain engineering approval.
Before placing products on the rack, inspect the complete assembly.
Check that all bolts and connection devices are installed.
Confirm that arms are level and correctly locked.
Confirm that uprights and bases are plumb and aligned.
Check that braces are not missing or damaged.
Verify that anchors are installed and tightened.
Confirm that the rack does not interfere with doors, sprinklers or emergency routes.
Install load capacity signs where operators can see them.
Complete any required commissioning or controlled load test.
Do not treat a load test as permission to exceed the rated capacity. The rack must remain within the lowest applicable rating for the arm, level, upright, base, anchor and floor.
Load the rack gradually and observe its behavior. Begin with correctly bundled products and keep the load centered over the arms.
Place the heaviest approved products at the lowest practical level.
Keep bundles centered from front to back and side to side.
Prevent round pipes from rolling toward the aisle.
Use straps, stops, dividers or cradles where the product requires retention.
Keep product overhang within the approved design limits.
Do not push bundles against uprights or neighboring products.
Load one bay at a time and check for abnormal movement.
Update the inventory and location records immediately.
Round pipes and tubes can roll unexpectedly when a bundle is cut open or when only part of the bundle is removed. A storage rack should be designed for the real picking method, not only for the fully strapped bundle.
Use end stops or raised arm lips where compatible with the handling method.
Use separators to keep different pipe sizes apart.
Keep loose pipes in cradles, boxes or controlled bundles.
Do not place loose round products on a flat arm without a retention solution.
Remove straps only when the operator has controlled the material.
Keep operators out of the potential roll path.
Timber may bend, slide or change weight when moisture conditions change. Boards may require continuous decking instead of separated arms.
Support flexible timber at enough points to limit sagging.
Use dunnage of consistent thickness to keep bundles stable.
Keep wet or damaged timber in a designated area.
Do not mix very different bundle weights on the same rack level without checking the design.
Store sheet goods on suitable decking or horizontal supports.
Keep timber away from heat sources and blocked sprinkler discharge areas.
Long loads require more careful forklift control than standard pallets. The load may obstruct the operator's view, swing during turns or strike an adjacent rack.
Inspect the forklift and attachment before use.
Confirm that the attachment is rated for the load and length.
Approach the rack squarely and slowly.
Keep the forks or lifting arms level before entering the bundle.
Lift only high enough to clear the supporting arm.
Keep the load low while traveling.
Use a spotter when visibility is restricted.
Travel at a controlled speed and sound warnings at blind corners.
Do not allow pedestrians inside the loading exclusion zone.
Withdraw the forks completely before turning away from the rack.
Inspection frequency should follow local regulations, the rack supplier's instructions and the intensity of use. High-traffic warehouses normally need more frequent checks.
Daily operator check: Look for impact damage, missing pins, displaced products and visible overloading.
Weekly or routine management check: Review upright alignment, arm condition, labels, braces and aisle clearance.
Formal periodic inspection: Have a competent person assess the rack and document any defects.
After an impact: Stop using the affected bay until it has been assessed.
After a layout change: Confirm that the new arrangement does not exceed the original design assumptions.
Mark damaged components and remove them from service until repaired or replaced. Do not straighten damaged structural members on site unless the repair method has been approved by a qualified engineer or the rack manufacturer.
A long product is not automatically a heavy product, and a short bundle may create a much higher load. Rack selection must consider weight, load distribution, support spacing and the total load on the upright.
Better practice: Submit actual bundle weights, dimensions and loading patterns to the supplier before requesting a quotation.
An arm rating does not always represent the safe capacity of the complete rack. Uprights, bases, bracing, anchors and the concrete floor may have different limits.
Better practice: Request a complete load table showing arm, level, upright and bay capacities.
A bundle may place most of its weight on a small contact area. This can overload an arm or damage the product even when the average weight appears acceptable.
Better practice: Confirm contact points, support width, arm spacing and load distribution with the rack manufacturer.
Long products extend beyond the forklift and can swing during turning. A narrow aisle increases impact risk and slows every picking operation.
Better practice: Design the aisle around the actual forklift, attachment, product length and turning method.
Uncontrolled round products can fall from an arm or roll into an operating aisle. This is one of the most serious risks in pipe storage.
Better practice: Include end stops, lips, cradles, dividers or other retention devices in the original design.
A strong steel rack cannot compensate for weak, cracked or uneven concrete. Poor floor conditions can affect alignment, anchoring and overall stability.
Better practice: Confirm floor strength, thickness, levelness and anchor suitability before finalizing the purchase.
A warehouse may change its stock lengths, bundle weights or order volume after the rack is installed. A system designed only for today's inventory may become inefficient quickly.
Better practice: Include adjustable arms, spare capacity and a future expansion plan where practical.
A low-priced quotation may exclude installation, anchors, safety stops, load signs, delivery, engineering drawings or after-sales support.
Better practice: Compare the complete delivered and installed cost, technical documentation, warranty, spare parts and service response.
Drilling new holes, welding arms, removing braces or changing arm positions can change the structural performance of the rack.
Better practice: Require written approval before modifying any load-bearing component or changing the original layout.
Even a correctly engineered rack can be damaged by poor forklift operation, uneven loading or incorrect product removal.
Better practice: Train every operator on load limits, location rules, rolling-product control, impact reporting and inspection procedures.
A clear request for quotation helps suppliers provide comparable designs and prevents missing items from appearing as additional costs later.
Material types and product descriptions.
Minimum and maximum product lengths.
Product diameter or cross-section.
Maximum bundle dimensions.
Maximum bundle weight.
Required number of storage positions.
Required rack height and total row length.
Single-sided or double-sided rack requirement.
Required arm length and number of levels.
Required load per arm, level and bay.
Indoor or outdoor installation conditions.
Floor material, thickness and known load capacity.
Forklift type, attachment and operating aisle requirement.
Required safety lips, stops, dividers, decking or cradles.
Paint or galvanizing requirements.
Delivery location and installation access.
Required drawings, manuals and inspection documents.
Warranty, spare parts and after-sales service requirements.
What is the rated capacity of each arm?
What is the rated capacity of each complete level?
What is the maximum load on each upright and base?
How was the load distribution calculated?
What floor and anchor assumptions were used?
Are the arm positions adjustable after installation?
How are round pipes prevented from rolling?
Can the design support future bays or additional arms?
What components are included in the quoted price?
Who is responsible for installation and commissioning?
What inspection and maintenance schedule is recommended?
What is the procedure for replacing damaged components?
Are load signs and operating instructions included?
What documentation will be supplied after completion?
Use a weighted comparison so that safety and operating performance are not overlooked.
Technical compliance: Does the proposal meet the load, dimension and layout requirements?
Safety: Does it include suitable retention, anchoring, guarding and load identification?
Usability: Can operators load and retrieve products without unnecessary handling?
Flexibility: Can arm levels or bay quantities be changed safely?
Quality: Are materials, welding, coating and inspection standards clearly stated?
Installation: Are delivery, unloading, assembly and commissioning included?
Support: Are spare parts, training and periodic inspection services available?
Total cost: Does the price include all required accessories and site-related costs?
Confirm the inventory list and maximum bundle weights.
Confirm the rack type, configuration and dimensions.
Approve the warehouse layout and traffic plan.
Verify aisle widths using the actual handling equipment.
Verify rack, floor and anchor capacities.
Confirm pipe retention and timber support details.
Review all drawings, load tables and quotations.
Confirm inclusions, delivery terms, installation scope and warranty.
Approve labels, load signs and operator instructions.
Schedule installation, inspection and staff training.
The design process should continue after installation. A warehouse racking system remains safe and useful only when it is inspected, operated and modified correctly.
Keep an updated rack layout and component inventory.
Record all impacts and repairs.
Replace missing safety pins immediately.
Keep aisles free from overflow stock.
Review rack utilization as product demand changes.
Do not add levels or increase loads without technical approval.
Inspect coating damage and corrosion, especially outdoors.
Review forklift routes after changes to the warehouse process.
Train new operators before they use the rack.
UNISTAR can help purchasing teams and warehouse planners evaluate cantilever rack layouts, storage capacities, handling requirements and long-material storage accessories. A successful project combines accurate product information, a suitable warehouse racking system, professional installation and consistent daily control.
When the design is based on real loads, real aisle conditions and real operating behavior, the warehouse racking system can store pipes, timber and long materials more safely while improving access, capacity and long-term purchasing value.
