Catwalk Systems
The catwalk system consists of an overhead beam with shelves. Warehouse catwalk systems are employed in warehouse storage for storing both standard products and heavy, bulky item(s) on shelving or racks. Catwalk storage facilitates help with locating goods by providing the ability to easily access products.
Most catwalk systems can come custom to fit your warehouse space and are made of a combination of steel beams along with pallet rack or boltless style components. This system makes it easier for items that can be lifted with forklifts without disrupting the flow of operations. Catwalk storage is also common in office warehouse environments where stock-keeping units (SKU) and off-the-shelf products are kept on racks.
Warehouse Solutions, Inc. offers a huge amount of new and used products, including boltless shelving and pallet rack catwalk system components.
Pallet Rack Catwalk System
The catwalk storage system is commonly used in manufacturing warehouses and distribution centers. This system consists of a steel beam supported at intervals by columns or posts which are tied to the support structure. Warehouse catwalk systems work well for storage because ladders and step stools do not need to be used when accessing products.
The warehouse catwalk system is usually installed in the ceiling area of a warehouse or storage facility, and goods are located on racks or shelves in alcoves formed by the steel beams and columns. Pallet rack catwalks can be used for stock-keeping warehouse items with heavyweight requirements, most have a 3,000 lb. capacity per square inch. Some warehouse pallet racks are designed so that forklift trucks can pass beneath shelves.
Basic Types of Material Handling Equipment in a Catwalk Storage System
The main type of warehouse equipment used to store on catwalks is storage racks – pallet rack, shelving, or cantilever shelving. A forklift truck is commonly used to move stock-keeping units (SKUs) or inventory from the storage racks down onto a pallet below the catwalk. In addition, trolleys or carts are also used on catwalks for moving packaged goods between different locations within the warehouse.
Design Considerations of Catwalk Systems
The following are some design considerations to think about for your catwalks.
Check-Rails
Check-rails are generally installed on the warehouse catwalk system approximately every six feet, but check-rails can be installed at various intervals that are required by operations.
Beams
Beams of warehouse catwalk systems are made up of two pieces, which may be rectangular or H-sections, and are connected with bolts or welds. The warehouse beam is attached to the support columns at each end by brackets for strength and support.
Support Columns
Warehouse catwalk systems can be supported with posts or steel columns, both of which are referred to as pallet rack support beam supports. Warehouse post supports can be attached directly to a concrete floor and the steel column supports require a small bracket for each column.
Ceiling Support
Catwalks typically have a clearance of 8 to 10 ft (2.5 to 3 m). The warehouse catwalk system is attached to the warehouse ceiling by a steel beam support structure.
Warehouse Lighting
Lighting is necessary for optimum visibility when inspecting warehouse inventory on pallets. Warehouse lights can be mounted in trusses or wooden ceiling supports of catwalk systems.
Catwalk storage designs include shelving systems with skylights. Proper lighting and skylights allow operators to view inventory from the floor below.
Special Considerations
The following are some special considerations to think about for your catwalk system such as forklifts and shipping or receiving docks.
Forklifts
Forklifts should weigh between 10,000 and 20,000 pounds depending on the capacity of the warehouse catwalk system and pallets that are being used to store goods. Forklifts should have a wide wheelbase for stability when driving on the warehouse catwalk.
Shipping or Receiving Docks
Docks are required wherever there is a warehouse storage system that extends beyond the walls of a warehouse and requires a place to offload bulk items from cargo trucks. Warehouses with forklift systems should have at least two shipping or receiving areas, which means two separate warehouses. Where cargo trucks are incapable of driving through warehouse storage doors, a receiving dock is installed at the door for unloading pallets from cargo trucks.
Who Should Use a Catwalk System
Catwalk warehouse storage has an open design that makes warehouse management easier. These management tasks can include the inspection of inventory on pallets for damaged goods and the loading of forklift trucks and pallets. Management of inventory flow is enhanced with the installation of a catwalk system.
Catwalk warehouse storage is a solution for operators who are required to work high on ladders. Catwalks provide an alternate storage method that reduces the need for personnel to work from above ground level and eliminates the use of ladders.
If you are looking for a better solution to better access to products, utilize free space or areas in your warehouse, and all with the safety of operators in mind, the catwalk system is for you!
Cautions Regarding Catwalk Systems
With the installation of a catwalk system, warehouse personnel should be trained in catwalk safety. This training should contain information on equipment including safety items such as safety harnesses and hard hats. Regular maintenance checks should also be done to ensure the safety and efficiency of the catwalk.
Warehouse Safety Harnesses
Safety lanyards, safety harnesses, catwalk kits, and tie-off cables are designed for catwalk use. Certain warehouse catwalks have a built-in safety harness system. These harnesses allow operators to move about the high catwalk and help keep operators safe in case of a fall.
PPE (Personal Protective Equipment)
Operators handling pallets on racks and shelves should wear safety goggles to prevent eye injury. Hard hats can help protect workers’ heads from accidental impact with beams, racking, and fixtures. When using a forklift truck, operators should wear a hard hat, safety goggles, and work gloves.
Warehouse Hard Hats
Operators are required to use a hard hat any time there is a risk of head injury like when working above ground level or working in high warehouses. Hard hats are also mandatory for personnel operating mobile lifts such as forklifts, pallet jacks, or stacker cranes.
Regular Maintenance for Catwalk Systems
Maintenance is necessary because catwalks will be subject to wear and tear over time, especially from forklifts. Check-rails need to be greased or lubricated periodically, while check-rail supports should be inspected for signs of wear or damage.
Pallet rack warehouse catwalks are easy to maintain. Check-rails and support beam brackets should be greased regularly to ensure smooth, free movement of products.
Warehouse Solutions, Inc.
With Warehouse Solutions, Inc., each system is custom-designed to the customer’s needs and warehouse configuration as well as local building and fire codes. Warehouse Solutions, Inc. has a large inventory of used new and used boltless shelving and pallet rack catwalk system components. For more information or to find out if a catwalk system will work for your operation, please call our office and speak to one of our Sales Engineers at (800) 278-1715.