Rack Supported Warehouse (Clad Rack)
Comprehensive storage system in which the racking forms the structure of the warehouse. Space optimisation, cost savings and faster implementation.
The product
Clad rack: great height and maximum storage capacity
Clad rack warehouses are buildings whose main structural component is the racking. The racks bear the weight of the goods stored in addition to the side and roof cladding and external agents, such as wind force. Therefore, rack supported buildings require minimal civil works, which streamlines assembly and reduces costs compared to traditional construction systems.
Rack supported warehouses make the most of all available space and can reach heights of up to 45 m. They also stand out for their great versatility: they can be designed to incorporate several types of storage solutions, from conventional and drive-in/drive through racking to fully automated storage and retrieval systems (AS/RS). Mecalux accompanies its clients throughout the project, from the preliminary calculations and design phase to the warehouse’s commissioning.
Advantages of clad rack warehouses
- Fast, simple construction: project implementation times for rack supported buildings are shorter compared to traditional warehouses. Moreover, they require minimal construction.
- Cost savings: the investment is also lower than that required for traditionally built facilities.
- High-bay storage: clad rack warehouses can be up to 45 m tall. Their height is only limited by local regulations and the reach of the handling equipment used.
- Optimal utilisation of surface area: the warehouse and racking are designed simultaneously. They occupy only the necessary space, without any intermediate columns.
- Maximum versatility: rack clad buildings can be configured with the storage system that best meets each need. These range from conventional and drive-in/drive-through racking solutions operated with forklifts through to fully automated storage and retrieval systems (AS/RS).
- Low-temperature storage: these rack supported structures can also function as cold storage and freezer warehouses.
- Strength and safety: rack supported warehouses are extremely robust structures designed to withstand the effects of external forces such as wind, snow loads and seismic movements.
- Demountable: the structure is primarily formed racking with components that are assembled or bolted together. Therefore, it can be easily dismantled, allowing for the recovery of a high percentage of components.
With the clad rack warehouse installed by Mecalux, we can store up to 15,000 pallets, which would be impossible in a traditional warehouse
Types of clad rack warehouses
Rack supported buildings adapt to multiple operational needs and requirements
The structure of a clad rack warehouse can be designed from a wide array of storage solutions. These can range from conventional and drive-in/drive-through racking to fully automated storage and retrieval systems (AS/RS) that use robotic equipment to handle loads.
Automated clad rack warehouses
Rack supported warehouses equipped with AS/RS such as pallet stacker cranes maximize the use of available vertical space, reaching heights of up to 45 m.
Rack clad buildings for cold storage
Rack supported structures are also employed in designing and assembling cold and freezer stores to house goods at low temperatures. These warehouses can be built using manual or automated storage solutions.
Manual rack supported warehouses
In these clad rack warehouses, operations are performed with forklifts. The pallet racking can be conventional (single- or double-deep) or high-density (drive-in/drive-through, push-back, flow or the Pallet Shuttle system). Their height is conditioned by the reach of the forklifts used.
Design and operation of clad rack warehouses
Extremely robust buildings with quick assembly
Rack supported buildings are projects that require a thorough structural analysis. However, the construction work involved is minimal, and they are built within a short time frame. The process consists of various phases, encompassing the warehouse design, manufacture and assembly.
Preliminary calculations
The warehouse calculation and design phase considers the stress that the racking must withstand, actions that may affect the structure, and the applicable regulations in force, among other factors.
Floor slab construction
The construction of the warehouse begins with the foundation of the concrete slab on which the structure will stand and the installation of the drainage pipes. Additionally, depending on the facility’s intended use, a perimeter sealing wall may be built.
Racking installation
The structure is assembled starting with the installation of the racking, typically at the front of the warehouse.
Fitting of cladding
Once the first racking structures are set up, the first roof and façade cladding sheets are attached. The process is sequential and progressive: the cladding panels are installed as the racking assembly advances.
Incorporation of handling equipment
In automated clad rack warehouses, after the installation of the first racking units and cladding panels, the handling equipment (e.g., stacker cranes) is introduced.
Receiving and shipping areas
The receiving and shipping areas are located in a traditionally built facility attached to the rack supported building.
Assembly completion
Finally, the racking is fully assembled, and the remaining cladding is installed.
Testimonials
The automated rack supported building was designed in a modular way. That is, we can expand the warehouse as our production pace quickens, adding more aisles to the five we have now.
We chose Mecalux as our supplier because of its experience in building clad rack warehouses. Moreover, its high-quality products can be adapted to our metal containers.
The rack supported warehouse has radically changed our logistics infrastructure. It’s helped us boost productivity in moving, storing and shipping our goods. Additionally, this solution has optimised available space, improving the organisation of the finished goods that leave the production lines.
The biggest advantage of the rack supported building Mecalux built for us is we’ve made the most of our storage space, thus increasing capacity. Plus, we’ve connected our two warehouses, which is great for business.
Choosing Mecalux to build our automated clad rack warehouse was driven by factors such as the company’s international experience in numerous diverse projects and the attractive pricing it offered.
“We’re thrilled with the automated clad-rack warehouse. It’s provided us with highly accurate stock control, improved our responsiveness and enabled us to supply the calibration and packaging area in under three minutes. As a result, we’ve enhanced the quality of our service and cut costs; we don’t have to stop production due to a lack of supplies.”
Case studies
Advantages of the clad-rack and Pallet Shuttle systems in an Argentinian poultry business cold storage
Mecalux has built a clad-rack cold storage in Argentina for the company Granja Tres Arroyos, specialised in poultry products. In order to maintain and enhance the growth rate achieved in recent years, the warehouse has been fitted with a high-density, semi-automated Pallet Shuttle system. This allows the company to obtain a capacity of more ... Read more
A 100% automated, turnkey warehouse for Würth in La Rioja
The German fastener, connector and assembly component company Würth has opened a new automated clad-rack warehouse in La Rioja (Spain). This very large installation means the company can supply its Wúrth stores throughout Spain, as well as customers who have purchased tools, drill bits, nuts and bolts online. Read more
The international chemical powerhouse consolidates its presence in Brazil with an automated clad-rack
Automation success story in the BASF warehouse in Brazil designed by Mecalux and other examples of storage systems Read more
Mecalux stands alongside Congelados de Navarra in its steady growth
Case study automated clad-rack chambers for Congelados de Navarra in Spain designed by Mecalux and other examples of storage systems. Read more
Delaviuda achieves a capacity for 22,000 pallets in 2,209 m2 in a new 42 m high automated warehouse
Automation success story in the Delaviuda warehouse in Spain designed by Mecalux and other examples of storage systems. Read more
Next-generation automated clad-rack warehouse: a sure bet to streamline of logistics processes at Cepsa
The energy company Cepsa entrusted Mecalux with the construction of a 37 m tall automated, turnkey warehouse in its lubricants production facility in the town of San Roque (Cádiz). The Mecalux Easy WMS warehouse management system has also been included in the set up, and is responsible for managing all the activities of the centre. Read more
The pharmaceutical laboratory Kern Pharma builds a clad-rack warehouse that combines stacker cranes for boxes and for pallets
Success story of warehouse automation at Kern Pharma in Barcelona (Spain) developed by Mecalux and other examples of storage systems. Read more
Two clad-rack warehouse for San Benedetto’s non-alcoholic drinks
San Benedetto, an Italian alcohol-free drinks producer, has renovated its logistics installation in Valencia (Spain). Mecalux has constructed two clad-rack warehouses with pallet racks, drive-in racks and live pallet racks allocated to finished product storage. The company will expand its drinks business. Read more
Mecalux builds one of the largest automated clad-rack warehouses in Europe
Case study of the automation of the Hayat Kimya warehouse in Turkey developed by Mecalux and other examples of storage systems. Read more
Components of a rack supported warehouse
The primary feature of a clad rack warehouse is that the racking that comprises it supports several elements: the stored loads, the thrust of the handling equipment, the other structural components (roof and side cladding) and external agents (wind forces, snow loads, seismic movements, etc.).
The basic structure of a clad rack warehouse is formed by three main elements: the racking, concrete floor slab and cladding (both roof and façade panels).
A rack supported building can be configured from a wide range of pallet storage solutions, from conventional and high-density racking to fully automated systems.
Safety is a priority in the design, choice of materials and assembly of Mecalux rack supported warehouses. They comply with regulations in force and meet various fire protection requirements.
Racking
The racks constitute the main structural component of a clad rack warehouse. They support their own weight, the weight of the cladding (roof and façades) and the weight of the stored goods. Moreover, they withstand external factors that typically affect buildings (such as wind force or roof overloads).
Floor slab
The warehouse structure is assembled on a concrete slab with the appropriate thickness to achieve an even distribution of forces on the base floor.
Cladding
The cladding panels for the building’s roof and façades are fitted to the racking through the upper truss and the roof and façade purlins. The engineering study allows for the installation of any type of cladding available in the market (for cold stores, for example).
Selective pallet racking
Pallet racking is ideal for warehouses that manage a wide variety of SKUs, as it offers direct access to each pallet. Double-deep and narrow-aisle rack configurations are also available.
High-density racking
High-density storage solutions such as pallet flow racking and the Pallet Shuttle system maximise the use of available space, significantly increasing warehouse capacity.
Automated storage & retrieval systems (AS/RS)
Racking operated with stacker cranes completely automates the placement and removal of unit loads, boosting warehouse productivity.
High-density AS/RS
Designing clad rack warehouses with solutions like the Automated Pallet Shuttle (with stacker cranes or transfer cars) offers a twofold benefit: complete automation of operations and optimisation of available storage space.
Non-flammable materials
The racking is made of steel and treated with a non-flammable coating.
Fire detectors
Clad rack warehouses are compatible with the installation of different fire detection systems (smoke, flame and/or temperature detectors, etc.).
Automatic fire suppression systems
During the clad rack warehouse design phase, it is possible to plan for the installation of automatic fire extinguishing systems, such as water spray sprinklers.
FAQs
The definition of a clad rack warehouse is simple: it is a type of building in which the racking constitutes the main structural component of the construction system. For this reason, in a clad rack warehouse, the racking supports its own weight, that of the stored goods and that of the roof and façade cladding; the stresses of the handling equipment; and the action of external agents, such as wind force and roof overloads due to snow.
A pallet rack supported building is the perfect solution for achieving a short construction time frame and significant cost savings compared to traditional systems. It is also an ideal alternative for maximising the use of available floor space, regardless of building height. Likewise, this construction system is recommended for cold storage and freezer warehouses.
Mecalux has extensive experience in designing, manufacturing, and assembling rack clad buildings for a wide variety of sectors. These range from the automotive, pharmaceutical and petrochemical industries to food, metallurgy and ceramics.
The civil work involved in building a clad rack warehouse is minimal. It is limited to the construction of the concrete slab upon which the structure will stand and, if necessary, a perimeter sealing wall.
Clad rack warehouses have multiple benefits, although two stand out: faster construction and lower initial investment compared to traditionally built facilities. As the racking itself constitutes the building’s main structural component, the required civil work is minimal. This approach results in considerable cost savings as well as speedier assembly and commissioning.
However, due precisely to the nature of the storage system’s structure, modifications applicable to it are limited. Nevertheless, clad rack warehouses are easily disassembled, making it possible to recover a large share of their components.
Rack supported buildings can be designed using a wide variety of storage systems. For example, selective pallet racking and drive-in/drive-through racking systems can be installed for load handling using forklifts. Meanwhile, automated storage and retrieval systems (AS/RS) — e.g., stacker cranes and the Automated Pallet Shuttle — completely automate product loading and unloading from the racking.
Mecalux’s clad rack warehouses are compatible with any type of cladding available in the market. It just needs to be defined in the design and preliminary calculation phase.
The height of a rack supported building is only conditioned by the regulations in force and the reach of the handling equipment employed. In an automated clad rack warehouse, for instance, it is possible to install racking measuring up to 45 m high.
Indeed. The construction system of a rack supported building can also be used in designing and assembling cold storage and freezer warehouses. In fact, it is the perfect solution for building these kinds of facilities, as the building occupies only the space necessary to house the racking. This maximises energy efficiency, resulting in significant cost savings.
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