Heavy-Duty Gravity Flow Racks
Structurally reinforced gravity flow systems rated for extreme loads in continuous industrial environments — engineered from your load data, not catalog assumptions. Designed and manufactured in Auburn Hills, MI.
Structurally reinforced gravity flow systems rated for extreme loads in continuous industrial environments — engineered from your load data, not catalog assumptions. Designed and manufactured in Auburn Hills, MI.
Every upright, beam, and rail section is sized by structural calculation based on your actual load data — not selected from a catalog tier that may under- or over-specify for your application.
Roller diameter starts at 75mm for heavy-duty lanes and scales to 90mm+ for extreme loads. Steel tube wall thickness and bearing size are matched to the lane load rating with a minimum 2:1 safety factor.
Speed-limiting braked rollers or hydraulic speed controllers are specified per lane to manage load velocity on descent — preventing impact damage at the pick face and protecting personnel.
Multi-tier systems include intermediate cross-bracing and load-transfer beams to maintain structural stiffness at height. Tier spacing accounts for load height plus mast clearance for your specific lift equipment.
Hot-dip galvanized uprights and rail, stainless steel rollers, and weather-sealed bearings are available for outdoor, wash-down, food-grade, and chemical-exposure environments.
Modular Solutions provides stamped structural drawings, anchor bolt details, and load certification documentation as part of every heavy-duty system project package.
75mm minimum; 90mm and 100mm available for loads above 2,000 lbs per lane position
Up to 5,000 lbs per pallet position; engineered ratings above 5,000 lbs on custom request
Heavy-gauge hot-rolled steel; wall thickness per structural calculation; galvanized or powder coat finish
2.5–5%; calculated per load weight and roller specification; speed controllers mandatory ≥3%
Single to four-tier; intermediate bracing at each tier; falling object protection available
Custom to lane depth; anchor-bolted base plates sized to column load and seismic zone
Custom to pallet or container footprint; guide rail clearance specified per load type
Braked rollers or hydraulic controllers per lane; calibrated to target 0.3–0.5 m/s pick-face velocity
Stamped structural drawings, anchor details, load certifications, and installation instructions included
Gravity flow staging for large, heavy subassemblies and components at production line-side positions.
High-density FIFO pallet storage for heavy industrial products, machinery parts, and capital equipment.
Bundled bar stock, coil, and plate staging in gravity lanes for sequenced pick and processing.
Hot and cooled casting staging in heavy-load lanes with heat-resistant roller and rail options.
High-cube tire pallet storage with gravity flow replenishment to shipping staging or line feed.
Galvanized heavy-duty lanes for outdoor lumber, building materials, and large component staging.
Secure, high-load gravity flow lanes for aerospace subassembly kits and defense logistics staging.
Drum and IBC gravity staging with containment-compatible rail and chemically resistant coatings.
Heavy-duty gravity flow racks are engineered for loads above 1,000 lbs per lane position. This requires larger-diameter rollers (75mm+), heavier-gauge steel rail, wider column uprights, and deeper cross-beam members compared to standard carton or tote flow racks. Every structural member is sized by load calculation, not by standard catalog selection.
Uprights are base-plated and anchor-bolted to the concrete floor using appropriately sized anchors for the column load. Anchor bolt size and embedment depth are calculated based on the maximum expected rack load and seismic zone. Modular Solutions provides stamped anchor drawings as part of the project documentation.
Yes. Multi-tier heavy-duty flow rack structures are designed with intermediate beams and cross-bracing to maintain structural rigidity at height. Tier spacing is set to accommodate the pallet or container height plus forklift mast clearance at each tier. Falling object protection and safety netting can be added between tier levels.
Standard finish is powder coat over zinc phosphate primer. For environments with high humidity, wash-down, or chemical exposure, hot-dip galvanized uprights and rail are available. Stainless steel roller tracks are available for food-grade and pharmaceutical applications requiring full wash-down compatibility.
Typical lead time from order to ship is 6–10 weeks for standard configurations. Complex multi-tier systems with custom dimensions, special surface treatments, or integrated sensing may require 10–14 weeks. Modular Solutions confirms lead time in writing at order placement.
Provide your load data, pallet dimensions, lane count, and environment — our engineers will calculate and quote a certified system.
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