Not all teardrop style pallet rack components are compatible or interchangeable.  Unfortunately, there isn’t an authority or institute that doles out specification standards for “teardrop” punched beam to upright connections.

There are three main components to modern roll-formed pallet rack which are beam channel, connector plate and an upright.  The connector plate is configured with either rivets, fingers, tabs or clips that attach to a complimentary designed upright.

Pallet rack designs, specifications and availability may come and go.  Even the same manufacturer has been known to vary these details over a period of time.  Differences in rivet diameter, rivet location, connector plate thickness are critical in compatibility.  Manual safety lock features were mandated by OSHA a few decades ago to protect the forklift operator who accidentally lifts their pallet load into the bottom of the load beam above.  Compatibility of these important mechanisms should be accounted for as well.  Surprisingly an 8 foot beam is not always 96 inches between the uprights.  Some could be 96-1/2” and another may be 96”.  Mixing the two in the same bay may spell problems galore.

The bottom line though is undamaged rack is always better than damaged.  It’s always best to replace any damaged components, even with some of the disadvantages that come with mixing varied beams and uprights from different sources.

Try considering replacing entire bay sections rather than one piece. That way you’ll know your connecting components are compatible.  Also you can avoid compatibility issues by simply adding an extra upright next to your existing upright rather than connecting new beams to old uprights or vice versa.

There are many disadvantages to below dock unloading applications.  Amongst them are inherent safety issues, potential equipment damage and "end-loaded" pallet accessibility.

Obviously the logical solution is to consider raising the truck bed level higher to match or exceed the existing dock height.  This is accomplished with the use of Wheel Risers.  

There are several types of wheel risers manufactured for different applications.  Width per riser is most common with 24" over 18" to help provide a convenience for the driver because of the dual wheels. Steel is more of a standard than the aluminum because of the overall weight versus cost factors.  If portability of the risers is in high regard then ordering them with fork pockets for moving them about with fork lifts is more feasible.

Maximum height differential of truck bed to dock should determine the height of wheel riser units (normally 6" to 12") in two inch increments.  Length ordered is determined by single or tandem axles being used and axle type/placement to the end of the trailer. 

Two very popular models that provide an extra safety and convenience factor is the Wheel Riser - SWR-24-8-84 which has an 8" height and is overall 84" long and the Wheel Riser - SWR-24-10-96 with 10" high x 96" long.  Always confirm if the units are ordered and priced each or pair.  The stated models are ordered 2 each.

Philadelphia Macaroni Company found their wheel risers to be the perfect solution for those uncommon type and sized trucks.

Their niche is to transport product quickly and effortlessly from point A to point B on a horizontal plane.  Fully powered is defined as powered lift and powered forward and reverse in functions.  Some other names for these units include powered walkies, motorized pallet trucks, mobile pallet trucks and forklift pallet trucks.

Variations that are common are "Walkie" versus "Rider" types, lift load capacity and service time operation between recharging of their batteries.  The higher the Ah rating of the battery configuration normally relates to longer service durations.

The two models shown above are atypical units required of a smaller to medium duty distribution warehouse. The first illustrated Pallet Truck - Electric Powered 3,000# capacity uses two 12V batteries and was found to be the perfect fit for Business Interiors of Idaho's requirements.

The second model Pallet Truck - Electric Powered 4,500# capacity uses four 12V batteries for a 180 Ah rating.

Being made of quality polymer plastic means it won't dent, chip or bend and it's light weight provides extra maneuverability and quiet operation.  Unit capacity is a formidable 500 lbs while each tray is sized at 24" x 36".  The molded handle assembly includes a convenient cup holder and storage slot for organization while the casters are non-marking on lino floor covered office areas.

It is many of these benefits that has prompted Blueprint Specialties to use these carts as their main material handler.

It is made in many materials, configurations and sizes but the "down and dirty" type is manufactured with steel, shipped "knocked down", has two shelves, casters and a handle.  

The height of most units are 32" high with the two most commonly used sizes for them are listed in the catalog as Service Cart Steel 2 Shelf KD 1630 (16"x30") and Service Cart Steel 2 Shelf KD 2436 (24"x36").

Varied supply, distribution and manufacturing operations have needs to utilize such equipment to move materials.  Woodland Manufacturing is one of the largest manufacturers and distributors of sign letters, wooden letters, plastic letters and metal letters.  They have several of these units in operation to help facilitate their efficiency.

An everyday example would be attempting to move a standard two-door storage cabinet.  There are numerous products made that fall into this category.  Boise Fitness Equipment has such a dilemma transporting their quality commercial grade fitness equipment. 

The best solution determined was to utilize a specialty handtruck that over the years has been called many names such as an appliance truck, bulk mover dolly or transporter, heavy duty vending machine two-wheeler. 

There are many variations to this type of equipment but uncomparably one of the best for this niche of handtruck is Wesco's model WRV-66 heavy duty vending machine truck.  It includes safety features within the quality of it's structure such as the retractable wheels to help support the load in transit.

Recently, Boise State University, expanded their Student Union Building. 

The facility staff at Boise State's SUB have been a client of mine for many years.  After the expansion and remodeling project was completed, we determined that additional basic material handling products would be required.  The features needed were versatility, durability and longevity.

Foresight into the benefits of quality construction of product took us into the category just up from entry level units.  Handtrucks whose structural steel weight is more than that of a cheaper model have reasons it may be better constructed. Those reasons include a larger diameter or thickness of structural tubing, heavier bracing at pressure points, use of stair-climbers, a thicker nose plate and larger diameter wheel axles with bearings. Having steel wheel protectors on this Heavy Duty P-handled Handtruck is a plus as well.

The second piece of equipment chosen was Akro-Mils Platform Truck Plastic Versa/Deck.  Akro-Mils has been the leader in the durable plastics sector of material handling storage for decades and their Versa/Deck platform cart system is renowned for its true versatility and durability.

The total integration of proper manual material handling products in a distribution process is dependent upon many factors.  Some of these factors may be obvious such as the type of material being transported, locations within the facility, surface conditions, any limitations (eg aisle space) to transport the goods and also the staff resources that are available.

It's my intention to write this article as an introduction of the more common categories of mobile material handling equipment that may be a solution to your specific requirements.  Subsequently, my follow up articles will delve into more detail of the specification variances of a type of equipment within a particular category.

The types are in no particular order.  One of the most popular pieces of equipment is the common two-wheeled handtruck for transporting unitized or boxed loads.

Platform trucks are able to move a larger volume of goods but require more aisle space and turning radius.  Deck surfaces are composed of steel, wood or plastic and different configurations are possible.

Another common category are Service carts or trucks.  These normally have two or three shelf levels.  The units are made of welded steel, bolt together metal components, durable plastic and chrome wire.

A more specialized category would be mobile Hoppers or Tilt Trucks.  This category is related to bulk load material such as chips and laundry. They are also used for refuse collection and disposal.  These carts/trucks are commonly made of very durable plastic or sometimes steel.

One such recent innovation is the P-Caddy which is molded from the durable and pliant plastic and is an invaluable and inexpensive accessory to most current pallet trucks in the industry.  This product acts as a helpful organizer, workstation and briefcase for your warehouse personnel.

This is an instance where illustrations better interpret what voluminous verbiage can't.

Attachment to your existing pallet jack is a simple operation as shown below.

The P-Caddy dimensions are as shown below.

A unique but productively shaped unit is the single forked pallet jack.  There are skids that are manufactured to store upon them odd shaped or sized product.  Bulk storage and distribution of this type of product using skid methodology of material handling via pallet truck with a single fork has proven itself most efficient over the years.

An example of this would be the church furnishings being manufactured by The Marshall Company which for over 70 years has offered their distinctive product throughout the western United States and Canada. They take pride in producing top notch furnishings and take it a step further than many others by manufacturing their own heavy duty skids to help ensure the furnishings arrive at their destination intact and without damage.

One size of Pallet Truck with Single Fork is 48" long x 12 or 9" wide with a 3,000 lb capacity that seems to meet many of the specialty built long narrow skids.

The unit shown maintains a 3 year warranty on it's pump so the quality factor I've written about in previously published blogs still applies.