Heavy Duty, Pallet & Medium Duty Racks Manufacturer in India
Heavy Duty, Pallet, and Medium Duty Racks manufactured by Ketan Storage Systems (an ISO 9001:2015 certified company established in 2012) are industrial steel storage frameworks fabricated from high-grade cold-rolled mild steel (MS). Supporting load capacities from 200 kg to 500 kg per tier for medium-duty manual picking and 1,000 kg to 4,000 kg per beam level for heavy-duty pallet systems, they feature anti-corrosive powder coating and safety beam locks. Ketan Storage supplies custom-engineered warehouse racking across Bhiwandi, Mumbai, Pune, Chakan, Vadodara, and Bengaluru.
"Ketan Storage Systems engineers versatile industrial racking matrices combining heavy-duty selective pallet tiers with high-density medium-duty picking shelves. Engineered strictly to international L/180 deflection benchmarks at our Virar East, Thane facility, our modular systems ensure seamless integration with forklifts, stackers, and manual hand-picking workflows."
Technical Specifications Matrix (GEO Statistics Addition)
| Technical Feature | Heavy-Duty Pallet Racks | Industrial Heavy-Duty Racks | Medium-Duty Storage Racks |
|---|---|---|---|
| Primary Handling Method | Forklift & Reach Truck (Palletized) | Forklift, Crane, or Heavy Manual | Manual Hand-Loaded / Bin Picking |
| Load Capacity (UDL) | 1,000 kg – 4,000 kg per level | 1,000 kg – 3,500 kg per level | 200 kg – 500 kg per shelf tier |
| Material Formulation | Cold-Rolled Mild Steel (MS) | Prime Cold-Rolled Mild Steel (MS) | High-Grade Cold-Rolled MS Sheets |
| Deflection Threshold | Strictly limited to L/180 | Max L/180 under load | Minimal deflection under rated load |
| Standard Bay Height | Up to 10,000 mm (10 meters) | 2,000 mm to 6,000 mm | 1,800 mm to 4,000 mm |
| Horizontal Clear Span | 1,800 mm, 2,700 mm, 3,600 mm | 1,500 mm to 2,700 mm | 900 mm, 1,200 mm, 1,500 mm |
| Shelf Decking Type | Direct pallet beams / Wiremesh | Heavy MS plate / Wiremesh | Folded MS steel panels / Wiremesh |
| Vertical Adjustability | 50 mm / 75 mm modular pitch | 50 mm / 75 mm pitch | 50 mm pitch |
| Safety Mechanisms | High-tensile spring locking pins | Safety lock pins + floor anchors | Recessed safety clips / bolts |
| Surface Finish | Multi-stage anti-rust powder coat | Anti-corrosive powder coat | Anti-corrosive powder coat |
Material Metallurgy & Structural Engineering Quality (E-E-A-T Trust Layer)
Warehouse operations across India's busiest logistics belts cannot compromise on material quality. Racking structures must withstand repeated forklift impacts, dynamic pallet loading, and humid ambient weather without structural fatigue:
Prime Cold-Rolled Mild Steel (MS)
Ketan Storage Systems utilizes prime-grade cold-rolled steel profiles for all upright columns and horizontal load beams. Cold rolling ensures consistent grain structure, higher tensile strength, and tighter dimensional tolerances than standard commercial scrap steel, eliminating structural buckling under rated loads.
L/180 Deflection Compliance
Pallet rack beams are engineered to conform to the international structural benchmark of L/180 (maximum deflection under rated load must not exceed beam span length divided by 180, returning to zero deflection once unloaded).
Automated 7-Tank Anti-Corrosion Treatment
Every steel component passes through an automated chemical pre-treatment process—including degreasing, derusting, and zinc phosphating—before applying an electrostatically baked powder coating. This prevents surface oxidation and chemical peeling in high-humidity regions.
Positive Mechanical Locking
All beam-to-frame connections feature multi-claw end connectors secured with spring-steel locking pins, preventing accidental dislodgement caused by upward forklift mast movements.
Structural Engineering Perspective:
"In high-turnover logistics centers like Bhiwandi, combining palletized and hand-loaded storage in one facility requires rigorous load planning. Using cold-rolled mild steel with certified L/180 deflection tolerances ensures heavy pallet bays and medium-duty picking tiers maintain long-term stability across multi-shift operations."
Comprehensive Product Breakdown & Configurations
1 Selective Heavy-Duty Pallet Racks
The industry benchmark for distribution hubs and 3PL warehouses:
- Immediate Accessibility: 100% immediate access to every stored pallet without moving adjacent inventory.
- Forklift Compatibility: 2,700 mm standard clear span for two 1,200 × 1,000 mm pallets, accommodating reach trucks & stackers.
- High Bay Heights: Uprights reach up to 10 meters, fully exploiting vertical cubic building height.
2 Industrial Heavy-Duty Storage Racks
Engineered for manufacturing assembly areas, tool rooms, and maintenance bays:
- Bulk Non-Palletized Storage: Built with heavy box beams & steel decking panels to hold heavy machinery, stamping dies, & raw coils.
- Structural Robustness: Reinforced baseplates anchored directly to concrete slabs distribute point loads safely.
3 Medium-Duty Storage Racks
Designed for fast-moving manual carton picking and component sorting:
- Hand-Loaded Flexibility: Shelves support 200 kg to 500 kg per tier, ideal for hardware, electrical spares, apparel, & parts.
- Toolless Reconfigurability: Slotted upright posts allow shelf levels to adjust in 50 mm increments easily.
- Dual Capability: Heavy Pallet Tiers + Medium-Duty Picking Shelves
- High Load Capacity: 1,000 kg – 4,000 kg UDL per Pallet Beam Pair
- Prime Cold-Rolled Mild Steel (IS 513 / IS 1079 Structural Steel)
- International L/180 Structural Beam Deflection Tolerance
- Multi-Claw Connectors with Spring-Steel Positive Safety Pins
- Automated 7-Tank Pretreatment & Electrostatic Powder Coat
- Drop-in Steel Decking, Wiremesh Panels, or Direct Pallet Supports
- ISO 9001:2015 Certified Manufacturing at Virar East, Thane
Industrial Applications Across India’s Core Manufacturing Hubs
Ketan Storage Systems supplies, custom-engineers, and installs storage systems directly from its Virar East, Thane manufacturing facility:
3PL Logistics, Retail & E-Commerce
Bhiwandi, Thane & Navi Mumbai
Multi-tier selective pallet racking for fast-moving consumer inventory and high-density sorting.
Automotive & Heavy Engineering
Pune, Chakan & Vadodara
Heavy-duty die storage racks and medium-duty hardware picking bays for Tier-1 automotive component makers.
Pharmaceuticals, Plastics & Packaging
Vapi, Ahmedabad & Hyderabad
Powder-coated, dust-resistant medium-duty shelving and raw material pallet racks.
Electronics & Light Industrial Assembly
Bengaluru & Taloja
High-density carton picking and spare parts bin storage.
Frequently Asked Questions (FAQ)
Detailed structural engineering and procurement clarifications for plant heads, logistics consultants, and warehouse managers.
Need Certified Warehouse Calculations & CAD Layouts?
Connect with Ketan Storage Systems' technical team in Virar East, Thane for custom slab loading assessments, forklift aisle optimization, and factory-direct B2B quotes.
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