Stack Rack Options & Accessories

Stack Rack with Perforated Steel Decking

When an application demands the rugged durability of a solid metal deck combined with open drainage and reduced unit weight, a stack rack with perforated steel decking offers the ideal balance. Constructed with a reinforced B-4 base featuring 4-way forklift entry, this 14-gauge steel decking setup allows workers to load heavy boxes, bags, and skids without damaging the deck structure. The die-punched perforated pattern lets water, dust, and debris pass directly through, preventing fluid accumulation during outdoor yard storage or staging on loading docks. This self-draining design lowers total tare weight for cheaper freight shipping while supporting sprinkler water penetration to comply with facility fire safety standards.

Stack Rack with Steel Fork Runners

Adding heavy-duty steel fork runners to stack rack bases solves the critical problem of point loading by distributing thousands of pounds of inventory weight along continuous floor channels rather than concentrating it solely on the four corner pin feet. Available in 2-way or 4-way entry configurations, these flush-mounted bottom runners prevent pin feet from gouging, cracking, or damaging concrete plant floors, trailer beds, and underlying wire decking when stored inside static pallet racks. Furthermore, steel runners act as rigid guides for forklift tines, protecting the lower frame from impact damage and giving drivers a clear visual target for safer, centered lifts.

Stack Rack with Fork Stirrups | Fork Guides

Fork stirrups (also known as fork guides) consist of heavy-duty, U-shaped steel straps welded to the underside of the stack rack frame to anchor the rack to the forklift tines during lifting and transit. Typically installed in pairs on opposite sides—most commonly along the widest or longest dimensions to ensure optimal weight balance—these guides prevent tall, long, or unbalanced loads from sliding off the forks during sharp turns or sudden stops. Standard stirrup spacing is set at 24″ on-center (O.C.), but custom spacing can be fabricated to match specialized fork carriages. While optional, fork stirrups deliver an added layer of safety and driver confidence, particularly for long, unwieldy rack frames or over-the-road trailer loading.

Stack Rack with Removable Side Bars

Stack racks equipped with removable side bars provide vertical product containment while maintaining total access to stored inventory. These heavy-duty steel bars connect the vertical corner posts to prevent boxed goods, loose rolls, or stacked cartons from tipping sideways into warehouse aisles, protecting personnel from falling object hazards and preventing costly inventory breakage. For ultimate flexibility, operators can easily lift the side bars out of their retention brackets to load or pick items from any side. Operations looking for a budget-friendly alternative can opt for factory-welded 2″ x 4″ post brackets, allowing teams to use economical wooden 2×4 lumber as removable side containment rails.

Stack Rack with Removable Side Frames | Side Rails

For high-volume transit and heavy industrial storage, stack racks with side frames—available as either permanently welded panels or removable rail assemblies—deliver maximum side containment across the full height of the rack. These side rails prevent shifting loads from bulging outward, allowing drivers to “cube out” 53-foot freight trailers safely and tightly without risking cargo damage against trailer walls. The open framework keeps contents visible for rapid stock counts without unloading, while the removable variants allow the entire structure to collapse for compact nesting when returning empty on backhauls.

Stack Rack with Solid Steel Decking

Built for high-impact industrial loading, stack racks with solid steel decking feature a heavy-duty reinforced B-4 base covered in smooth, 14-gauge solid steel. This design creates a continuous, rigid surface capable of withstanding rough handling, heavy drop-loading, and sharp machinery parts that would destroy lighter decking materials. The smooth steel deck functions as a heavy-duty portable steel shelf, allowing wooden pallets, metal bins, and irregular items to slide on and off without catching. It provides complete, uninterrupted bottom support for small, loose, or odd-shaped items that cannot bridge open mesh gaps.

Stack Rack with Plywood Decking

Plywood decking represents a cost-effective decking upgrade for facilities needing a smooth, continuous surface on a budget. Supported by a heavy-duty tubular steel base frame, 1/2″ or 3/4″ CDX plywood panels provide an even, non-marking platform ideal for stacking cartons, soft goods, and specialized tooling. Facilities can purchase these units fully assembled with factory-installed plywood or save on freight costs by ordering the steel frames and retrofitting locally sourced, custom-cut plywood onto the base. If a wood panel experiences heavy wear or damage over time, it can be unbolted and replaced quickly without taking the steel rack frame out of service.

Stack Racks with Casters and Fork Stirrups

Combining a set of four 6″ x 2″ casters with factory-welded fork stirrups creates a highly versatile hybrid storage frame that transitions between manual pushing and forklift transport. Workers can roll these multi-functional racks directly down assembly lines or order-picking aisles to hand-load parts, then use a forklift to lift and stack the secure, stirrup-anchored frames up to 4 units high in central storage bays. If retrofitting existing stock racks with stirrups in the field, note that the added stirrup components will ship unpainted unless specified and installed during original factory production.

Stack Rack Options & Accessories

Customizing stack racks with purpose-built accessories ensures your material handling system aligns with unique operational demands:

• Fork Stirrups: Steel U-straps welded to base frames (standard 24″ O.C. spacing) that lock onto forklift tines for secure transport; available in 2-pair or 4-pair sets.
  
• Steel Runners: 2-way or 4-way continuous bottom channels that eliminate point-loading on concrete floors and distribute heavy weights evenly across underlying pallet rack decks.
  
• Fork Tunnels / Pockets: Full-length, enclosed steel tubes welded beneath the base frame to completely envelop forklift tines for maximum stability during overhead lifts.
  
• Side Frames & Side Bars: Welded or removable vertical steel barriers that tie corner posts together to prevent product tipping and improve trailer loading density.
  
• Custom Decking Options: Choose from 14-gauge solid steel, 14-gauge perforated steel, 2″ x 4″ x 5-gauge wire mesh, or 1/2″ CDX plywood to match specific load support and drainage requirements.
  
• Custom Powder-Coat Finishes: Standard industrial blue finish with custom options for seven standard colors or exact corporate RAL color matching.
  

Frequently Asked Questions

Can portable stack racks equipped with casters be rolled while they are stacked vertically?

No. Stacking stack racks that are mounted on casters and trying to roll them in a stacked position creates a severe tip-over hazard and is strictly discouraged. Casters are designed for rolling individual, single-tier racks across smooth concrete floors or into delivery trailers. Once a caster-equipped rack is placed into its final storage location, it can be stacked vertically using a forklift, but it must remain stationary until the upper tiers are unstacked.

How do I choose between solid steel decking, perforated steel, and wire mesh decking for my stack racks?

• Solid Steel Decking: Best for heavy-duty point loads, rough drop-loading, and supporting small or irregularly shaped parts that require a completely flat, non-snagging surface.
  
• Perforated Steel Decking: Ideal when you need the structural strength of solid steel combined with lighter tare weight, air circulation, and liquid drainage for outdoor staging.
  
• Wire Mesh Decking: The most popular choice for general warehousing, offering high visibility, minimal dust accumulation, and maximum overhead sprinkler water penetration for fire code compliance.
  

What is the benefit of specifying custom RAL powder-coat colors for stack racks?

Beyond matching corporate branding, applying custom powder-coat paint colors serves as a practical inventory management tool. Facilities often color-code their stack racks by department, product line, SKU category, or destination (e.g., green for raw materials, blue for work-in-progress, red for finished goods). Custom powder coating also provides a durable, scratch-resistant barrier that protects the underlying steel against rust and corrosion in active industrial environments.