Bulk Storage Racks

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Bulk Storage Racks without Decking
Bulk Storage Racks with Solid Decking
Bulk Storage Racks with Ribbed Decking
Bulk Storage Racks with Wire Decking
Bulk Storage Racks with Particle Board Decking
Bulk Storage Rack Parts & Accessories

Bulk Storage Racks

Heavy-Duty Bulk Storage Racks for Hand-Loaded Warehouse Storage

Bulk storage is the in-between problem in most facilities: cartons, cases, and parts that are too heavy or too large for standard shelving, but not stored on pallets or moved with a forklift. Bulk storage racks are built for exactly that kind of hand-loaded inventory.

Every rack in this collection is made by Lyon from powder-coated steel, with 14-gauge welded uprights, 14-gauge Z-beams, and levels rated from 1,650 to 2,600 lbs depending on beam width. Complete starter and add-on units come with solid steel, ribbed steel, galvanized wire, or particle board decking in 60", 72", and 96" widths, 24", 36", and 48" depths, and 72", 84", and 96" heights.

Planning a full row or a larger project?

Our team can help you work out the sizes, decking, and parts list. Request a quote or call 866-801-9829.

What Is a Bulk Storage Rack?

A bulk storage rack sits between industrial shelving and pallet racking. It uses the same basic build as a pallet rack, with welded uprights and beams that lock into place, but it is sized and rated for goods that people load by hand: cartons, cases, bins, parts, tools, and other non-palletized inventory. Each level holds far more weight than a typical steel shelf, and the beams adjust on 1.5" centers so the levels can be moved as your inventory changes.

Choosing the Right Bulk Storage System for Your Load

Bulk storage racks are not the only way to store large or heavy inventory. The right system depends on three things: how big the items are, how much they weigh, and whether they are handled by hand or with lift equipment.

Storage System Best For How It Is Loaded
Boltless Shelving Lighter boxes, bins, and supplies where you want more shelves in less vertical space By hand
Bulk Storage Racks Heavy cartons, cases, and parts up to 2,600 lbs per level that are too large or heavy for shelving By hand
Pallet Racks Palletized loads and high-volume inventory stored in full pallet quantities Forklift or lift equipment
Cantilever Racks Long items like lumber, pipe, tubing, and bar stock that would hang off a standard rack By hand or forklift

If your loads are heavy, boxed or loose, and picked by hand, a bulk storage rack is usually the right fit. If they are palletized, or longer than a 96" wide rack, one of the other systems will serve you better.

Decking Options

Comparing Bulk Storage Rack Decking Types

The frame and beams are the same across this collection. The decking is what changes, and it should be chosen based on what you are storing, how it is picked, and what your facility requires for fire protection.

Solid Steel Decking

A smooth, uninterrupted steel surface that keeps small items from falling through and helps contain leaks and spills. A good fit for mixed inventory, loose parts, and fluids stored in containers.

Ribbed Steel Decking

20-gauge steel with 5/8" deep by 1-3/4" wide ribs. It gives you a solid surface, and the gaps between the ribs let workers get their fingers under cartons without pinching them.

Galvanized Wire Decking

5-gauge galvanized flat wire in a 4" x 2" mesh. The open grid lets light, air, and sprinkler water pass through each level, which is why it is often chosen where fire code calls for open decking. It also cuts down on dust buildup.

Particle Board Decking

5/8" thick particle board provides a flat, solid surface at the lowest cost. Best for dry, indoor storage of boxed goods where a steel deck is not required.

Racks Without Decking

Frames with beams and front-to-back supports but no deck surface. Choose these when you are supplying your own decking, storing items that span the beams on their own, or plan to add decking panels separately.

Bulk Storage Rack Weight Capacity by Beam Width

On these racks, the beam width sets the level capacity. Height and depth do not change it. Wider racks give you more shelf space per level, but each level carries less weight.

Rack Width Capacity per Level Best For
60"w 2,600 lbs The heaviest loads per level, such as boxed hardware, metal parts, and cased liquids
72"w 1,900 lbs A balance of shelf length and capacity for general warehouse stock
96"w 1,650 lbs Long or bulky cartons that need a wide opening more than a high weight rating

Capacities are for evenly distributed loads. Uprights are rated at 10,000 lbs per section, so add up the weight across every level in a bay, not just a single level. Decking panels also carry their own ratings, which are listed on each decking product page. Plan your loads around the lowest rating in the system.

Bulk Storage Racks Are for Hand Loading Only

Lyon rates these racks for manual loading and retrieval. They are not designed for forklift loading, and the posted capacities assume items are placed by hand and spread evenly across the level.

If your operation moves product on pallets or with lift equipment, look at pallet racking built and rated for that use.

Building a Row

Bulk Storage Rack Starter Units vs. Add-On Units

Every bulk storage rack in this collection comes as a starter or an add-on. Starter units stand on their own. Add-on units connect to the end of a starter and share its upright, so you can extend a row for less than the cost of a second starter.

Choose a Starter Unit When:

  • You are setting up the first bay in a row
  • You need a single freestanding rack
  • You are starting a new row in a different spot

Choose an Add-On Unit When:

  • You already have a starter unit in place
  • You want to extend an existing row
  • The new bay matches the starter's depth and height

A row of four bays is one starter plus three add-ons. Match the depth and height of your add-ons to the starter so they share uprights correctly.

How to Choose the Right Bulk Storage Rack Size and Configuration

Most ordering questions come down to a handful of decisions. Work through these before adding a rack to your cart.

Check these before you order:

  • Weight per level: Estimate the heaviest level you will load, then pick a width rated for it.
  • Depth: 24" works for cartons and cases, while 36" and 48" fit larger boxes. Leave room to reach the back of the level.
  • Height and levels: 72"h and 84"h units come with 3 levels, and 96"h units come with 4. Uprights are sold separately up to 144"h.
  • Decking: Match the deck to your items and to your facility's sprinkler requirements.
  • Row length: Measure the full run, then plan one starter plus the add-ons needed to fill it.
  • Placement: Decide whether racks will stand alone, sit against a wall, or run back-to-back, since each needs different hardware.

Expanding or Completing a Bulk Storage Rack Setup

Complete starter and add-on units include what you need to build each bay. When you are adding levels, building a custom height, or installing rows, you will also need a few separately sold components:

  • Extra levels: Sold with or without decking to add storage to an existing rack.
  • Front-to-back supports: Required on every level, even with decking. The quantity depends on beam width and decking type and is listed on the product page.
  • Anchoring and row hardware: Anchoring feet, back-to-back ties, back-to-wall ties, and tie plates keep racks secured and rows aligned.

Shop uprights, beams, decking panels, and hardware in bulk storage rack parts and accessories.

Where Bulk Storage Racks Are Commonly Used

Bulk storage racks are a common choice anywhere heavy, non-palletized stock needs to stay organized and within reach.

Warehouses and Distribution Centers

Case picking, overstock, and bulk cartons that are picked by hand.

Manufacturing Facilities

Raw materials, work-in-process, and boxed components near the line.

Maintenance and Parts Rooms

Heavy replacement parts, fasteners, fluids, and equipment.

Retail and Wholesale Back Stock

Heavier cartons and cased goods that would overload standard shelving.

Records and Archive Storage

Rows of file boxes, where weight adds up quickly across each level.

Garages and Service Shops

Tires, tool cases, and bulky supplies that need a sturdy rack.

Bulk Storage Rack FAQs

Answers to common questions about bulk storage rack capacity, sizing, decking, and installation.

How do I know if I need bulk storage racks instead of shelving?

Look at the weight and size of what is going on each level. If your items are heavy enough to bow a standard shelf, too large to fit on typical shelf depths, or add up to more than shelving is rated for, a bulk storage rack is the better fit. Bulk storage rack levels hold 1,650 to 2,600 lbs, depending on width.

Can I use a forklift to load bulk storage racks?

No. These Lyon bulk storage racks are rated for hand loading only. If you need to place or pull loads with lift equipment, choose pallet racking instead.

Do bulk storage racks need to be anchored to the floor?

Anchoring is recommended to keep the rack stable and protect workers and inventory, especially on taller units. Lyon's anchoring foot bolts to the upright and accepts a 3/8" x 3" concrete wedge anchor, which is sold separately.

How far apart can the levels be adjusted?

Beams adjust on 1.5" centers along the upright, so you can set each level to fit the height of what you are storing.

Can I add more levels to a bulk storage rack?

Yes. Extra levels are sold with or without decking and include the beams and front-to-back supports for that level. Keep the total weight across all levels within the upright's rating of 10,000 lbs per section.

What if my items are longer than the rack is wide?

The widest bulk storage racks here are 96". Items that would hang past the uprights, such as lumber, pipe, tubing, or bar stock, are better stored on cantilever racks. Their arms extend from a single column, with no front uprights in the way.

When should I contact Shelving.com before ordering?

Reach out if you are planning several rows, working around sprinkler or fire code requirements, adding onto racks that are already installed, or not sure which parts you need. Our team can put together a complete parts list and quote.

Bulk Storage Rack Resources

Learn more about planning, using, and maintaining bulk storage racking in your facility.

Industrial Cantilever & Bulk Storage Racking Guide

Compare bulk storage and cantilever racking systems and see which one fits your inventory, space, and loads.

Read the Guide →

Five Ways to Use Bulk Storage Racks

See how businesses use bulk storage racks for inventory, supplies, archives, and other heavy hand-loaded storage.

Read the Article →

RMI-Approved Rack Inspections

Learn how Shelving.com's rack inspections help keep installed racking safe and in line with OSHA requirements.

Learn About Inspections →

Need Help Planning Your Bulk Storage Racks?

Tell us what you are storing and how much space you have, and our team will help you choose sizes, decking, and the parts needed to finish the job.

Request a Quote Or call 866-801-9829
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Bulk Storage Racks

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We don’t just sell stellar shelves. We design custom organized spaces that fit your needs, large or small.

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Let Us Install For You

We don’t just sell stellar shelves. We design custom organized spaces that fit your needs, large or small.

We Can Help You