Storing long, heavy, or bulky building materials like lumber and piping isn’t as straightforward as stacking pallets of standard-sized boxes. These materials require specially designed pallet racking systems that ensure safety, stability, and accessibility. Whether you’re setting up a new yard or scaling an existing warehouse, understanding the ins and outs of proper racking is crucial.
In this FAQ guide, we’ll address the most common questions about pallet racking systems for storing lumber and piping—so you can design a setup that works for your operations, your staff, and your customers.
- What type of racking system is best for storing long materials like lumber and pipes?
The most effective solution is a cantilever racking system. Unlike traditional pallet racks, cantilever racks have:
No front columns
Extended arms that support long or awkward items
Open sides for easier loading and unloading with forklifts or side loaders
Cantilever racking is ideal for items like PVC pipes, steel rods, rebar, trim, and dimensional lumber.
- Can I use standard pallet racking for lumber or piping?
Not recommended. Standard pallet racking is designed for uniform, palletized goods. Trying to store long or uneven items on them can lead to:
Overhanging loads
Increased risk of tipping or collapse
Difficulty accessing materials without damage
For safety and efficiency, always use racking designed specifically for the shape and weight of your materials.
- What weight capacity do I need in my racking system?
This depends on the material type and how you stack it. For example:
Lumber bundles can weigh between 2,000–5,000 lbs.
Steel pipes may exceed that, depending on thickness and length
Your racking system must support both the weight per arm and per vertical column.
Work with a structural engineer or rack provider to calculate safe load limits. Never guess.
- How can I store both long materials and palletized items in the same space?
Use a hybrid racking layout that incorporates:
Cantilever racks for long goods
Pallet racking for boxed or bagged items
Floor stacking zones for oversized or hard-to-rack materials (e.g., roof trusses, insulation rolls)
Group zones by material type and handling method for maximum efficiency.
- Are there outdoor racking systems suitable for yards?
Yes—many suppliers offer galvanized or powder-coated cantilever racking systems designed for outdoor use. These are resistant to:
Rust and corrosion
UV exposure
Heavy precipitation and temperature swings
Ensure racking is securely anchored and rated for environmental exposure based on your region.
- What safety considerations should I keep in mind?
Racking collapses and falling materials are serious risks. Follow these safety practices:
Anchor all racks to the floor
Post clear signage for weight limits and load instructions
Conduct regular inspections for rust, damage, or structural stress
Train forklift operators on how to load/unload long materials without tipping
Include racking maintenance in your warehouse or yard safety audit checklist.
- How does racking design affect inventory access and picking speed?
Good racking design = faster, safer material handling. To maximize speed:
Store fast-moving SKUs at ground level or low-arm levels
Leave wide aisle spacing for maneuvering forklifts or side-loaders
Use vertical space efficiently, but avoid placing frequently picked items too high
Slotting strategy plays a huge role in reducing retrieval time for bulky materials.
- Can pallet racking be used in multi-yard operations with varied layouts?
Yes—but with careful planning. In multi-location distribution, it’s important to:
Standardize racking where possible for ease of training and maintenance
Adjust layout to fit the available space and climate at each yard
Use your ERP to track what’s stored where—including rack locations and SKUs assigned to each zone
Digitally mapping racking layouts into your ERP or WMS is a best practice for consistency and visibility.
- What’s the ROI on investing in proper racking systems?
While cantilever and heavy-duty racking systems can be costly upfront, the long-term savings include:
Fewer material damages
Faster loading and fulfillment times
Increased safety and lower risk of injury or insurance claims
Optimized space utilization (vertical + horizontal)
For high-turnover products like dimensional lumber and piping, the return on investment is typically realized within 12–24 months.
Final Thoughts
Choosing the right pallet racking system for storing lumber and piping isn’t just about fitting materials into a space—it’s about creating a safer, more efficient, and scalable operation. With the right setup, you can streamline workflows, reduce handling risks, and improve service levels for your contractors and builders.
