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Racking UAEBy Forton

Mobile Racking

Mobile racking systems mount pallet racks on motorized bases that move laterally to open aisles only where needed. This ...

Mobile Racking

Mobile racking systems mount pallet racks on motorized bases that move laterally to open aisles only where needed. This eliminates wasted aisle space and can increase storage capacity by up to 80% compared to static racking, making it ideal for cold stores and archives.

  • Up to 80% more capacity
  • Motorized base movement
  • Single aisle access
  • Cold storage ideal
Mobile Racking

Overview

Mobile racking systems represent the ultimate solution for maximizing storage capacity in space-constrained environments. By mounting conventional pallet racking on electrically powered mobile bases that move laterally on floor-mounted rails, mobile racking eliminates all but one working aisle at a time—dramatically increasing storage density by up to 80-100% compared to static racking installations.

The concept is elegantly simple: instead of dedicating permanent aisles between every row of racking, the entire racking block sits on motorized carriages that slide sideways to open an aisle wherever the operator needs access. When no one is working in the system, all rows compact together, leaving zero wasted aisle space.

Mobile racking is widely deployed in the UAE for cold storage facilities (where every cubic meter of conditioned space is expensive to maintain), archives and document storage, pharmaceutical warehouses, bonded goods storage, and any application where maximizing storage within a fixed footprint is the primary objective.

System Operation & Mechanics

Mobile racking systems consist of standard pallet racking mounted on electrically driven mobile bases (carriages). These carriages run on steel rails embedded in or laid on top of the warehouse floor. Electric motors drive the carriages via gear mechanisms, with each carriage capable of carrying loads of 500 tonnes or more.

The operator selects the required aisle using a control panel, remote control, or proximity sensor. The system then automatically moves the adjacent carriages apart to create an aisle at the desired location. Safety systems including photocells, floor sensors, and emergency stops ensure that no aisle opens while anyone is inside the system.

The most common configuration uses one "floating" aisle that can be opened at any position within the racking block. Some systems provide two or three simultaneous aisles for higher throughput operations, though this slightly reduces the overall density advantage.

The entire system is controlled by a PLC (Programmable Logic Controller) that manages carriage movement sequences, safety interlocks, and communication with the warehouse management system.

Mobile Racking system details

Advantages

Key Benefits

Up to 100% More Capacity

Eliminate all but one working aisle and store up to twice as many pallets in the same warehouse footprint.

Full Selectivity

Despite the high density, every pallet position remains directly accessible—just select the aisle you need and the system opens it automatically.

Energy Savings in Cold Storage

By reducing the volume of air that needs to be cooled, mobile racking can cut cold storage energy costs by up to 40%.

Advanced Safety Systems

Multiple layers of safety including photocells, pressure-sensitive floor mats, emergency stops, and warning lights ensure safe operation at all times.

Low Maintenance

Robust electric drive systems with sealed gear mechanisms require minimal maintenance—typically just annual servicing.

Automation Ready

Mobile racking can be integrated with automated guided vehicles (AGVs) and warehouse management systems for hands-free operation.

Industries & Use Cases

  • Cold and frozen storage (-30°C to +5°C)
  • Pharmaceutical and healthcare storage
  • Bonded and customs warehouses
  • Archive and document storage
  • Military and government storage depots
  • Wine and spirits storage
  • Museum and artifact storage
  • Hazardous materials storage

Technical Details

Carriage CapacityUp to 500 tonnes per base
Travel Speed4 to 6 meters per minute
Drive SystemElectric motor with gear reducer
Guide SystemFloor-mounted steel rails
ControlPLC with remote control option
Safety SystemsPhotocells, floor sensors, E-stops
Power Supply380V / 3-phase via cable festoon
Operating Temperature-30°C to +45°C

Cold Storage ROI Analysis

In cold storage applications, mobile racking delivers compelling economics. Consider a 2,000 m² cold room at -25°C: a static racking layout might provide 2,400 pallet positions, while mobile racking in the same space provides 4,500+ positions. The incremental cost of the mobile bases is typically recovered within 18-24 months through reduced per-pallet cold storage costs. Over a 10-year facility life, the total energy savings alone can exceed the entire mobile system investment.

Safety Systems in Detail

Our mobile racking systems incorporate multiple independent safety layers. Infrared photocell barriers at each aisle entrance detect personnel or equipment in the aisle. Pressure-sensitive rubber floor mats provide a secondary detection method. Emergency stop buttons are positioned at every aisle entrance and at regular intervals within the aisles. Audible alarms and flashing lights warn of impending carriage movement. The PLC-based control system monitors all safety inputs continuously and will immediately halt all movement if any safety condition is triggered.

FAQ

Frequently Asked Questions

Installation time depends on the system size and complexity. A typical single-run cantilever system with 10-15 columns can be installed in 2-3 working days. Larger projects with multiple runs and custom features may take 1-2 weeks. Our installation team works around your operational schedule to minimize disruption.

In the event of a power failure, the system locks in its current position with mechanical brakes. An uninterruptible power supply (UPS) can be added to allow safe completion of any in-progress aisle movements and to maintain safety system functionality.

In many cases, existing pallet racking can be mounted on mobile bases, provided the racking is in good structural condition and the floor can accommodate the rail system. Our engineers will assess the feasibility during a detailed site survey.

The floor must be level (±2mm over 2 meters) and have adequate load-bearing capacity for the concentrated rail loads. In most cases, standard industrial floor slabs are suitable. For new construction, we provide detailed floor specifications to the building contractor.

Double deep racking typically increases storage capacity by 30-40% compared to selective racking in the same footprint. This is achieved by reducing the number of aisles by approximately half. While not as dense as drive-in racking, double deep offers better selectivity since you only lose access to one pallet per bay.

All our drive-in systems include floor-mounted guide rails, column protectors at lane entries, end-stop beams, anti-collapse mesh panels, and clear signage indicating maximum load capacities. We also provide operator training as part of every installation.

Yes, mobile racking systems can support the same load capacities as their static equivalents. Heavy-duty mobile bases can carry total loads exceeding 500 tonnes per carriage. The rail system and drive motors are specified to handle the total weight with appropriate safety margins.

Standard mobile racking opens one aisle at a time. However, multi-aisle access systems are available that can open 2-3 aisles simultaneously by using wider blocks and additional drive mechanisms. This is useful in high-throughput environments where single-aisle access creates a bottleneck.

With proper use and regular maintenance, cantilever racking systems can last 20-30 years or more. The hot-rolled structural steel construction provides excellent durability. We recommend annual structural inspections and prompt replacement of any damaged components to maintain safety and extend the system's lifespan.

Mobile racking is very energy-efficient. The electric motors only run during aisle opening and closing movements, consuming minimal power. A typical system uses less energy than a standard office air conditioning unit. Some systems also feature regenerative braking that recovers energy during deceleration.

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