Custom OEM Longspan Shelving Manufacturers & Factories

While standard pallet racking is engineered primarily for mechanical forklift handling of unitized pallet loads up to 1,000–4,000 kg per level with open beam bays, longspan shelving is optimized for manual high-density carton and piece picking. Longspan utilizes lower-profile uprights (55×47mm or 55×55mm) and specialized step-beams recessed to receive solid steel decking panels, wire decking, or timber boards flush with the beam edge. Load ratings typically span 200 kg to 1,000 kg per tier, allowing wide clear-span pick faces (up to 2,700mm) without intermediate vertical column obstructions.

Load calculation follows European FEM 10.2.02 and SEMA standards based on a Uniformly Distributed Load (UDL) model. We conduct finite element analysis (FEA) on beam cross-sections to establish yield stress and moment of inertia. The permissible elastic deflection is governed by δ ≤ L/200, meaning a 2,000mm clear span beam will experience a maximum vertical center deflection of less than 10mm at full rated capacity. Crucially, beam safety pins must exhibit shear resistance >10 kN to prevent connector roll-out when eccentric manual loading occurs.

Standard commercial shelving often peels due to inadequate metal preparation. Our facility operates an automated 8-stage pre-treatment chemical tunnel comprising alkaline degreasing, twin water flushes, hydrochloric acid pickling (eliminating all mill scale and oxidation), zinc phosphating, and demineralized rinsing. This is followed by high-voltage electrostatic deposition of thermoset polyester powder (60–90 μm thickness) and 200°C baking. The resulting finish complies with ASTM B117 salt-spray standards (500+ hours), preventing flaking in humid coastal hubs (e.g., Dubai, Jeddah, Singapore, Miami).

To produce an engineered 2D CAD floorplan and structural quotation, our engineering team requires: (1) Building architectural CAD or dimensioned PDF showing clear height under roof joists and slab expansion joints; (2) Maximum dimensions and dead-weight of stored products or storage totes; (3) Required tier count per bay; (4) Preferred decking medium (cold-rolled steel panel, galvanized shelf, or drop-in wire decking); and (5) Local seismic zone coefficients if building permits require certified seismic baseplates and frame diagonal bracing calculations.

We provide full white-label and private-brand support: (1) E-Commerce Drop-Ship Packaging: High-burst strength 5-ply honeycomb export cartons passing ISTA 3A drop tests with individual shrink-wrapped sub-components; (2) Industrial Bulk Palletizing: Upright frames pre-assembled or flat-packed with heavy-gauge corrugated edge-protectors, plastic wrap, and steel banding configured for direct forklift unstuffing; (3) Custom Branding: Embossed client logos on beam end-connectors, customized assembly manuals, and serialized barcode labels matching client ERP SKUs.

Yes. Our heavy-duty longspan uprights (specifically our 80×60mm profile series) are engineered with high axial load capacity specifically to support 2-tier and 3-tier catwalk floors. The lower longspan uprights act as structural columns bearing the overhead aisle catwalk grid, handrails, staircases, and pallet drop gates. This doubles or triples operational warehouse picking capacity without the prohibitive structural cost of a separate hot-rolled I-beam mezzanine platform.

For standard powder-coated specifications (RAL 5015 blue, RAL 7035 light grey, RAL 2004 orange), our typical factory production cycle is 14 to 20 working days for full 20ft or 40ft High Cube container orders. Bespoke tooling for non-standard perforation geometries or custom roll-formed beam profiles requires approximately 25–30 days including pilot die extrusion and destructive load certification. Our baseline MOQ is generally one 20ft container (approx. 12–14 metric tons) to optimize international shipping economics, though sample trial orders are supported for verified distributor qualification.

Every shipment is accompanied by a project-specific CAD installation blueprint with distinct component color coding and numbered bundle tags corresponding to bill-of-lading container packing lists. Our boltless slot-in beam connectors require no specialized tooling—only a rubber mallet is needed for tier assembly. For complex high-bay or mezzanine installations, we provide pre-drilled floor anchor points, high-tensile wedge anchors, adjustable shims for uneven concrete slabs (±25mm compensation), and real-time video engineering supervision.