Steel bars, pipes and aluminium profiles 4–6 m long, and 1220×2440 mm MDF boards, are often leaned against walls or piled on the floor, where they fall over, bend and take time to find. PRIMEAG recommends a cantilever rack for long stock and a panel trolley for boards and large sheets, so each size has its own place and can be taken out without moving anything else.
- Long stock (pipe, bar, profile): cantilever rack – no front uprights, loaded from the long side.
- Large sheets (board, steel sheet, glass, acrylic): panel trolley holding sheets tilted, or an A-frame.
- One level or bay per size: label at the arm tip, readable from the aisle.
- Room to turn: size the aisle by the length of the stock, not by the rack depth.
Why long and large stock causes incidents
- Leaned against walls: pull one bar and the whole bundle slides, risking injury.
- Piled on the floor: getting the bottom bar means unloading the whole pile; stock resting on few supports bends.
- Boards stacked off-center: warping, chipped edges, scratched finish.
- Carrying large sheets by hand: two people must coordinate, sheets catch on doors and hit things.
The main cause is the storage method: using ordinary racks with front uprights for stock that does not fit the bays.
1. Cantilever racks for long stock
A cantilever rack consists of uprights at the back with arms projecting forward and no uprights blocking the front. Long stock lies across several arms and is removed horizontally by hand or forklift. Points to settle:
- Upright spacing: close enough that the stock does not sag between arms; flexible stock such as plastic pipe or thin profiles needs closer uprights.
- Overhang: stock should not project too far beyond the last arm.
- Load per arm: shown on a label; heavy stock on the lower levels.
- Arm end stops: stop pins so round stock (pipe, round bar) cannot roll off.
Single-sided racks go against a wall; double-sided racks stand in the middle of the shop and use both sides.
2. Panel trolleys for boards and large sheets
A panel trolley holds sheets tilted or upright between retaining bars, takes little floor space and can be pushed by one person from storage to the panel saw or CNC machine. Choose it by sheet size (usually 1220×2440 mm), thickness and the number of sheets per trip. Contact surfaces should have rubber or plastic padding so the finish is not scratched. Use industrial PU casters with brakes, and a larger diameter if the floor has grooves or ridges.
Sheets already cut into smaller parts (cabinet doors, table tops) move between processes on a multi-level steel pipe trolley, with level spacing adjusted to the parts.
Choosing racks and trolleys by type of stock
| Type of stock | Storage | Handling |
|---|---|---|
| Pipe, steel bar, aluminium profile 3–6 m | cantilever rack | Long-load trolley, forklift |
| Large MDF, plywood, steel sheet | A-frame, vertical sheet rack | panel trolley |
| Cut parts, semi-finished goods | medium-duty rack | multi-level steel pipe trolley |
| Crated goods on pallets | pallet rack | Forklift |
Custom-size racks and trolleys: new designs 10–15 working days (including drawing approval); standard designs 5–7 working days. Frame warranty 3 years, casters 12 months.
Self-check of the long-stock area
- Is any stock leaning against a wall or piled on the floor?
- How long does it take to get the bottom bar, and how many people?
- Are any bars bent, boards warped or edges chipped?
- Is the aisle wide enough to swing long stock without hitting people or machines?
Send PRIMEAG your list of sizes (length, width, weight per bundle) and the layout of the storage area to receive a proposal. Pre-cut moisture-resistant MDF for table tops and shelves: moisture-resistant melamine-faced MDF. Warehouse layout and pick-location rules: warehouse solutions for wrong picks and slow picking.
Frequently asked questions
How is a cantilever rack different from a standard rack? A cantilever rack has no front uprights; the arms project from uprights at the back, so long stock such as pipes, steel bars and aluminium profiles is loaded and removed horizontally without obstruction.
What information is needed to design a cantilever rack? The length, weight and number of bundles for each size, the type of stock (round or flat, rigid or flexible), how it is picked (by hand or forklift) and the floor plan of the rack area.
Can a panel trolley carry 1220×2440 boards? Yes. Panel trolleys are designed around the sheet size, thickness and number of sheets per trip, with padded contact surfaces so the finish is not scratched. New designs take 10–15 working days; frame warranty 3 years.
Updated: 14 October 2026 — PRIMEAG engineering team
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Written by the PRIMEAG engineering team
Updated: 2026-10-19