Efficient Steel Pallet Solutions for Pipe Storage Optimization

Streamlined Pipe Storage with Custom Stack Rack Systems

Efficient storage solutions are critical for industries handling long materials like pipes. This case study demonstrates how a construction materials supplier transformed warehouse operations using Derack galvanised stillages, a robust custom stack rack system designed for heavy-duty storage.

The Challenge: Space Constraints and Safety Risks

Businesses managing 6-meter plastic or steel pipes often face:

• Wasted vertical/horizontal space with traditional methods.
• Hazardous retrieval processes due to unstable stacking.
• Damage risks from bending or scratching during handling.
• Limited capacity from non-stackable storage units.

The client’s existing setup lacked the modularity of demountable post pallets, exacerbating inefficiencies

The Solution: Derack Galvanised Stillages

The steelpallet-based system addressed these challenges with:

1. Optimized Dimensions (1150mm x 950mm): Maximized storage density while maintaining forklift accessibility.
2. High Load Capacity: Each unit supports up to 2000kg, ideal for steel pipes or plumbing supplies.
3. Three-High Stackability: Enabled by custom stack rack engineering, tripling vertical space utilization.
4. Forklift-Friendly Design: Streamlined loading/unloading, reducing labor time by 30%24.

Key Benefits Achieved

1. Increased Storage Capacity: Stackable galvanised stillages expanded warehouse capacity by 200% within the same footprint.
2. Enhanced Safety: Secure containment minimized pipe damage and workplace hazards.
3. Cost Efficiency: Reduced shipping expenses with space-optimized packaging—24 units fit in a 40ft container (18 flat, 6 upright)4.
4. ROI-Driven Design: The demountable post pallets system’s durability ensured long-term savings on maintenance and replacements5.

Packaging and Logistics

Derack’s steelpallet units ship in standardized configurations:

• Cost-Effective Transit: Protective wrapping film and strapping prevent damage; optional wooden crates add security for international shipping.
• Localized Adaptability: Units comply with US/EU safety standards, with pricing in USD or EUR for regional transparency36.

Safety Protocols for Steel Pallet Systems

• Forklift Operations: Maintain steady speeds during loading to prevent structural stress on galvanised stillages.
• Routine Inspections: Check for weld integrity and base deformation monthly.
• Secure Stacking: Ensure demountable post pallets are fu