Metal racks for production: design
How metal racks for production are designed: shelf load, stainless or painted steel, modularity. We break down the choice of racks for a workshop.
A metal rack seems the simplest equipment in a workshop, yet it is often designed carelessly — “by eye”. The result: sagging shelves, an unstable structure, corrosion in a wet zone. A rack for production is a loaded structure that has to be calculated. This article breaks down how we design metal racks for real workshop conditions.
Calculating the shelf load
The first thing the design starts with is the real load. Customers often underestimate the weight: a crate of finished product, a pallet of raw material, a vat of semi-finished product weigh more than they seem. We clarify the weight of a storage unit, the number of units per shelf and calculate the uniformly distributed load. From it the shelf metal thickness and the upright cross-section are selected. We build in a safety factor of at least 1.5 — the rack must withstand even an off-design overload without permanent deformation.
Separately we account for the type of load. A uniformly distributed load (crates across the whole shelf) and a concentrated one (a single heavy vat in the middle) give different deflection at the same total weight. A concentrated load is more dangerous, so for racks under heavy vats and barrels we reinforce the middle of the shelf with transverse ribs or design the shelf from thicker metal. If the rack is to be loaded by a forklift, we add a margin for the dynamic impact when placing a pallet.
Choosing steel: stainless or painted
The second key decision is the metal grade. It depends on the workshop zone where the rack will stand.
| Rack type | Material | Application zone | Features |
|---|---|---|---|
| Food wet | Stainless AISI 304 | Washing zone, raw product | Does not rust, washable with water |
| Food dry | Stainless AISI 304 | Storage of open product | Hygienic, HACCP |
| General workshop | Powder-coated steel | Packaging store, spares | Economical, for dry zones |
| Heavy warehouse | Steel, hot-dip galvanized | Pallets, heavy loads | High load capacity |
For open-food contact zones and wet sections we always choose stainless steel AISI 304 — painted steel there quickly corrodes at chips. For dry storage zones a painted rack is more economical and fully justified.
Engineer’s tip. In a wet workshop do not save on the shelf steel grade, even if the rack does not directly contact product. Condensation and regular washing eat away powder coating in 2–3 years, after which rust appears and the rack fails a hygiene audit. Stainless steel costs more at the start but lasts the whole service life of the workshop.
Modularity and configuration
Production changes: the product range, volumes and workshop layout change. So we design racks modular. A modular design allows:
- Rearranging shelves by height for different containers without welding.
- Extending the rack in sections lengthwise.
- Dismantling and moving the rack when the layout changes.
- Replacing a single damaged shelf without replacing the whole structure.
We agree shelf height and pitch with container dimensions, and the width of aisles between racks with the sizes of trolleys and forklifts that will work there.
Stability and fixing
A tall rack is a matter of stability. We calculate the structure so it does not tip over even under uneven loading. Racks over 2 metres tall we fix to the wall or tie together into a block. Support feet are made adjustable — this compensates for floor unevenness and allows the rack to be set strictly vertical. We manufacture racks for production in the custom equipment section together with process tables and other workshop tooling.
Manufacture and surface finish
The way a rack’s elements are joined affects its longevity and repairability. A welded rack is more rigid but cannot be disassembled and is hard to move. A bolted one is modular, easily rearranged, but needs periodic retightening of the joints. For production workshops we more often choose a bolted design with stainless fasteners. Welds, where present, are ground smooth — an unfinished weld in a wet zone becomes a focus of corrosion and dirt accumulation.
The surface finish depends on the material. Stainless steel is polished or electropolished — a smooth surface holds less dirt and is easier to clean. Painted steel is coated with powder paint after priming; the quality of surface preparation here determines how long the coating lasts. For racks in food zones we avoid sharp edges and open tube ends — they are closed with caps so that moisture does not get inside the profile.
Conclusion
A metal rack is a loaded structure, not “shelves on legs”. A sound design starts with a load calculation, continues with the choice of steel grade for the workshop zone, and ends with modularity that gives flexibility for years. If you need racks for specific production conditions, get in touch — we’ll calculate the structure and manufacture racks for your workshop.
