Top Mistakes in Pallet Racking Systems for Storing Lumber and Piping — and How to Fix Them
Pallet racking is one of the most critical pieces of warehouse infrastructure for building materials distributors. But when storing oversized items like lumber, PVC piping, and conduit, it’s not just about how strong your racking is — it’s about how smartly it’s designed, labeled, and integrated with your workflow.
When racking systems aren’t optimized for these unique materials, they create daily bottlenecks, safety risks, and costly errors. Here’s a breakdown of the most common mistakes distributors make with pallet and cantilever racking systems for lumber and piping — and how to fix them for long-term efficiency.
Mistake 1: Using Standard Pallet Racking for Non-Palletized Materials
The issue:
Standard racking isn’t designed to handle long, unboxed items like 20-ft lumber, steel conduit, or coiled pipe. These materials hang over edges, bow under their own weight, or become unstable over time.
Fix it:
Use cantilever racking with adjustable arms for long goods
Install pipe cradles or horizontal bar supports to keep items straight and accessible
For coiled or flexible materials, use spool racks or ground-level cradles
Mistake 2: Not Labeling Rack Locations in the ERP
The issue:
When rack positions aren’t tied to your ERP, pickers rely on memory or guesswork. This increases the chance of mispicks, delays, and misplaced inventory.
Fix it:
Assign bin IDs to every rack arm, bay, and side
Use weather-resistant barcode or QR code labels
Ensure mobile scanning tools link directly to ERP location data
Update pick and putaway workflows to require location verification
Mistake 3: Stacking Materials Too High or Too Tight
The issue:
Overloaded racks not only risk material warping or breakage — they also put forklift operators and team members at risk.
Fix it:
Follow manufacturer-recommended weight limits for each rack arm
Leave clearance for safe material handling
Use load sensors or visual guides for high-turn zones
Designate oversize-only lanes that prevent blocking or overhang
Mistake 4: Mixing SKUs Within the Same Rack Slot
The issue:
It’s tempting to save space by putting multiple products in one rack arm — but this causes picking errors, poor FIFO rotation, and confusion.
Fix it:
Use color-coded signage or dividers for multi-SKU racking
Assign one SKU per rack position wherever possible
For fast-turn items, dedicate full rows or cantilever towers
Use ERP to enforce storage rules by product type
Mistake 5: Ignoring Environmental Exposure Risks
The issue:
Outdoor racking exposed to sunlight, rain, or dust leads to degraded material — and unusable inventory.
Fix it:
Cover outdoor racks with UV-resistant canopies or roofing
Place moisture-sensitive goods (e.g. MDF, bagged cement) under full cover
Use ERP-integrated IoT sensors to monitor temperature and humidity in storage zones
Rotate outdoor-stored materials more frequently (triggered by shelf life alerts)
Mistake 6: Underestimating Aisle Width and Forklift Access
The issue:
Long or bundled materials require wider turning space. Narrow aisles or poorly positioned posts lead to slowdowns and racking damage.
Fix it:
Design minimum 12–15 ft aisles for long-load forklifts
Use painted guides or signage for safe turning radius
Reserve central access lanes for oversized order staging
Routinely inspect racking for wear, bends, or missing pins
Mistake 7: Not Using Racking Data for Optimization
The issue:
Many distributors treat racking as static infrastructure — instead of a system that can evolve.
Fix it:
Use ERP reporting to monitor rack utilization, SKU movement, and staging efficiency
Rotate high-turn items to accessible lower levels
Consolidate slow-moving SKUs to free up premium real estate
Include racking layout reviews in quarterly ops strategy
Final Thoughts
Racking systems are more than steel arms and frames — they’re the foundation of safe, accurate, and scalable material flow. For long, heavy, and high-value building materials, investing in the right racking setup — and integrating it into your ERP workflows — pays dividends every single day.
Fixing just one or two of these common mistakes can lead to faster fulfillment, fewer damaged goods, and a safer, more organized yard.
