High-Density Multi-Tier Work Platforms for Global Logistics
Pick Modules engineered by UNARCO RACKING are multi-level structural work platforms designed to consolidate dynamic storage media, conveyor integration, and high-density product staging into a single unified distribution framework.
Engineered to satisfy the rigorous volume demands of global e-commerce, big-box retail, and third-party logistics (3PL) providers, our systems routinely process over 100,000 order lines per day. By elevating picking levels up to four tiers high within existing building clear heights, UNARCO RACKING pick modules multiply usable warehouse capacity while cutting order-cycle pick times by over 60%.
Our structures utilize heavy-gauge roll-formed or structural steel uprights to support miles of integrated takeaway conveyors, trash-handling lines, dynamic flow beds, and elevated mezzanine walkways with complete seismic and RMI (ANSI MH16.1) compliance.
1 to 4 Tier Elevations
Capitalize on vertical clear space up to 40+ feet high with certified mezzanine platforms, heavy-duty floor deckings, and integrated stairway systems.
Dynamic Gravity Flow
Gravity-driven Pallet Flow and Carton Flow roller lanes ensure automatic FIFO rotation and continuous replenishment at the immediate pick face.
RMI & Seismic Integrity
Engineered to site-specific building codes, IBC parameters, and RMI ANSI MH16.1 specifications with certified anchor embedment and seismic calculations.
Engineered Subsystems within UNARCO RACKING Pick Modules
Every component is engineered to operate harmoniously, ensuring continuous replenishment from full pallet staging down to split-case pick faces.
Pallet Flow Racks
Deep-lane gravity roller beds feed full pallet loads directly into pick areas from back-loading replenishment aisles, eliminating forklift and order-picker traffic congestion.
Push Back Systems
Nested heavy-duty cart configurations allow 2 to 6-deep LIFO pallet storage alongside pick towers, ensuring instant reserve product availability for high-velocity SKUs.
Carton Flow Lanes
High-durability Dura-Flex roller tracks and RhinoTrac full-width rollers provide ergonomic, paperless, or pick-to-light fulfillment with zero package snagging.
Conveyor Routing
Rack-supported powered roller conveyors, spiral gravity chutes, and empty-corrugated removal belts quickly channel completed orders directly to shipping docks.
Engineering & Fabrication Specifications
Manufactured with exact dimensional tolerances required for seamless automation, robotic interfacing, and multi-tier structural loads.
| System Attribute | Standard Specification Range | Engineering Advantage |
|---|---|---|
| Vertical Pick Levels | 1 to 4 Elevated Levels (plus ground level) | Multiplies warehouse footprint up to 400% without facility expansion. |
| Structural Materials | Heavy roll-formed 50 KSI minimum steel & structural hot-rolled channels | High impact resistance against material handling equipment at floor level. |
| Decking & Flooring | Heavy-gauge B-Deck with ResinDek panels, bar grating, or steel diamond plate | Engineered for continuous pallet jack wheel rolling loads, acoustic dampening, and fire compliance. |
| Replenishment Configurations | Full-case gravity flow, pallet flow lanes, push back racks, and static shelf bays | Complete separation of restocking lift trucks and split-case picking workers. |
| Safety & Egress | OSHA & IBC-compliant structural stairtowers, handrails, kickplates, and self-closing gates | Guarantees operator workplace safety and swift egress compliance across every level. |
| Surface Finish | Automated multi-stage pre-treatment and electrostatic thermoset powder coat | Superior scratch, wear, and corrosion protection for high-traffic environments. |
Configure Your Engineered Pick Module Project
Collaborate with UNARCO RACKING engineering specialists to model load ratings, seismic calculations, conveyor pathways, and workflow CAD designs. Contact our engineering desk directly at [email protected].
End-to-End Pick Module Delivery for Overseas DC Projects
A rigorous engineering process tailored for global logistics facilities, project managers, and systems integrators.
SKU Profile & Data Review
Analysis of product dimensions, weight profiles, pick velocity classes, and daily order fulfillment targets.
FEA & Structural Engineering
Complete static and dynamic load modeling, concrete slab verification, and site-specific seismic anchoring analysis.
Precision Fabrication
Tolerances fabricated to RMI standards with automated robot welding and heavy-duty powder coating.
Export Staging & Logistics
Bundling, moisture-sealed container packing, and coordinated overseas freight to global project sites.
Installation & Commissioning
Field engineering oversight, installation staging, and final commissioning support for seamless integration.
Frequently Asked Questions: Pick Modules
Answers to common structural and logistical questions from warehouse project directors and procurement managers.
What is the difference between a freestanding mezzanine and a rack-supported pick module?
A freestanding mezzanine is supported entirely by structural steel columns and beams, providing an open floor beneath. A rack-supported pick module utilizes the pallet rack upright frames and beams themselves as the primary load-bearing structural support for the elevated walkways and conveyors. This rack-integrated design delivers far higher storage density, lowers overall structural steel costs, and maximizes vertical cube utilization.
How does UNARCO RACKING integrate pick modules with conveyor systems?
Our engineers custom-design frame attachments, intermediate floor supports, and conveyor hanger brackets directly into the racking superstructure. This guarantees optimal vibration absorption, prevents line deflection, and maintains clean ergonomic access to both the picking face and the takeaway conveyor belt lines.
How do pick modules satisfy fire protection and sprinkler requirements?
Pick module designs are coordinated with NFPA 13 guidelines. UNARCO RACKING structures incorporate engineered longitudinal and transverse flue spaces, in-rack sprinkler pipe hangers, and slotted decking or heavy bar grating to facilitate adequate vertical water penetration in case of fire emergency.
Can existing selective racking be converted into an elevated pick module?
Converting existing racks into a multi-tier pick module requires a comprehensive engineering evaluation. Frame column section properties, base plate sizes, concrete slab thickness, and seismic anchor embedment must be recalculated to confirm they can safely carry the compounded loads of floors, conveyors, and personnel.
What documentation is required to initiate a pick module quotation?
To initiate a comprehensive preliminary design, share your building CAD floor plan with clear ceiling heights, column grid spacing, concrete slab specifications, pallet and carton dimensions with weights, pick velocity SKU data, and local building code or seismic requirements with our engineering team at [email protected].
Ready to Engineer an Optimized Multi-Level Pick Module?
Connect directly with our engineering team for warehouse layout planning and structural proposals: [email protected]