Pallet Rack Sheds

[WMichelsen]

I have several sections of pallet racks that I've cut down to 6ft (suburbia fence height). They are outside, and I need to enclose and weather proof them. Essentially, I'd like them to also function as framing for a long shallow shed (actually several).

Unfortunately, I'm struggling with the idea. Best I can conceive is to just bolt vertical 2x4s to all the corners and move on like regular wood framing. That's almost building a whole wood frame around the racks. They're pretty solid structures, and it seems there must be a better way to utilize them in this.

The general design is easy. For a 10' length section, I want 5' roller doors for access. The problem is how to use them for structure as well as shelving.

I'm sure others have forged this path before. What have you done?
TIA for any ideas,
Wayne

BTW, I did search the forum for similar posts, but came up dry. Please send me links if I missed them.

 

[FlaGman]

This is a pretty interesting video series on using pallets to make a shed

 

[ezover]

not a shed story but was interesting to me. I used to make delivery's to a warehouse that used pallet racking to make a entire second floor for storage.

 

[Rc_Guy]

This is a pretty interesting video series on using pallets to make a shed

Doesn't he wasn't too use pallet racking, not pallets?

You would think you could put purlins on racking and put siding on purlins,

 

[matt_i]

I built a wooden wall attached to a pallet rack inside of a plant.

The general design was bolt horizontal 2x4s to the uprights, no attachments to the load beams because of course it would weaken them, and if the beams were loaded up it would put downward pressure on the wall skin.

One could potentially use metal siding but you'd probably want a Z-shaped flashing at the bottom to keep out water and direct it over the edge of the concrete (?) slab.

Of some concern is bolting the pallet racks down at the corners of the slab, one doesn't really want to put an expansion wedge anchor near an outside corner. I think its imperative to put an anchor into each foot though as this not only keeps the building from tipping over due to wind side-loads but also its your uplift connection. On the endwall it would be a good idea to use metal X-bracing, even if its metal shipping banding.

As far as truss or rafter system I would consider wood again, crossing purlins and metal roofing. Like any wood-to-metal connection it takes some thinking here, ideal in my mind would be a metal flat that's welded to the top of the top of the teardrop column and then use a structural screw upwards into the wood framing thru a punched hole. Probably better to weld up this detail with the uprights on the ground....

 

[PNWguy]

I built a partition wall in a shared warehouse/work space out of pallet racks. I simply screwed sheetrock to the pallet rack with self tapping screws.

For something more permanent, I'd screw or bolt 2x4s to the rails and attach siding to the 2x's. I'd also spend some time making it really square, and bolting it to the concrete pad (assuming there is one).

I'm not sure you'd save that much money over stick building a shed.

 

[TurnipTruck]

I put three walls on a 20’ pallet rack as a wind wall. I had bought a huge pile of old overhead garage doors and used the “top hat” shaped stiffeners horizontally, screwed to the uprights, then the old door panels vertically, bolted to the stiffeners. I offset the uppermost beams and fit some rafters between and built a roof. Bypass door tracks could have easily been hung from the rafters, I just never got around to it.

 

[paredown]

This was one of my spring projects to store firewood. Made out of random pallets and some salvaged PT lumber from a deck demo. Shingles were from dumpster diving on a build--someone used our dumpster onsite and I dug 'em out. I think I was into it for about a $100 or so for hardware, nails, the 2x rafters and a couple of extra PT boards.

Pallets were nailed to PT sleepers, then flipped over, I face nailed the front supports from sleeper and front of pallets. Deck screwed the sides and back pallets together, and screwed those on to the base, then added back corner posts nailed to pallets. Roof structure you can see, and then I added some extra horizontal bracing on the inside where the pallets have the cutouts on the bottom boards. A late addition was the center brace between front and back to stiffen the structure a little more, and it also works well for isolating each pile of wood.

It is not art, but was stable enough that I got up on top to shingle.

My worst mistake is that the set of pallets I started with were a bit random--if I did it again I would try to find a set of good quality pallets that matched...

Whoops--I think I missed the point--pallet racking not pallets--but I'll leave this here.

 

[WMichelsen]

Thanks for the thoughts. Yes, I'm trying to build up from pallet racks (not wood pallets).
For the roofing part, I agree about purlins and trusses. And also, securing the footings. It seems the idea to bolt 2x4s around and build a wood structure shell is about where this is going.
Again, if anyone has actually done similar (with pictures or advice) I'd very much appreciate it.

Thanks,
Wayne

 

[Ehcrain]

If you plant to use the uprights and have any adjustment to the shelf height i would plan for a good 3 to 4 inches at the front and rear of the racking to allow the shelves to be placed. Maybe bolt a 2x8 to the outside edge of the racking and use the exposed edge to build off of. You could line the 2x up with the inside of the upright beam and it would give you the offset needed.

Sent from my SM-G950U using Tapatalk

 

[WMichelsen]

Agreed. As currently being planned, I'll use at least blocks of 2x4 near top, bottom, and maybe middle of the uprights as standoffs so I can retain the option to reposition the shelves. Thanks for your thought.

 

[Samh]

There is a build thread on here where someone is doing this for their shop

 

[TexasShooter]

https://www.garagejournal.com/forum/showthread.php?t=419187&highlight=PALLET+RACK

 

[WMichelsen]

Wow! That is an impressive project. Thanks for the link.
My needs are minuscule in comparison.

 

[ant.foste]

This was one of my spring projects to store firewood. Made out of random pallets and some salvaged PT lumber from a deck demo. Shingles were from dumpster diving on a build--someone used our dumpster onsite and I dug 'em out. I think I was into it for about a $100 or so for hardware, nails, the 2x rafters and a couple of extra PT boards.

Pallets were nailed to PT sleepers, then flipped over, I face nailed the front supports from sleeper and front of pallets. Deck screwed the sides and back pallets together, and screwed those on to the base, then added back corner posts nailed to pallets. Roof structure you can see, and then I added some extra horizontal bracing on the inside where the pallets have the cutouts on the bottom boards. A late addition was the center brace between front and back to stiffen the structure a little more, and it also works well for isolating each pile of wood.

It is not art, but was stable enough that I got up on top to shingle.

My worst mistake is that the set of pallets I started with were a bit random--if I did it again I would try to find a set of good quality pallets that matched...

Whoops--I think I missed the point--pallet racking not pallets--but I'll leave this here.

While you may have missed the target point of this thread, you certainly posted a very cool, cheap, and functional project.

 

[ant.foste]

not a shed story but was interesting to me. I used to make delivery's to a warehouse that used pallet racking to make a entire second floor for storage.

I have done this in three of my facilities now, but they are more of a low mezzanine than a 2nd story in order to stay below the 6' rule for (construction industry) fall protection. It works very well, goes up very quickly, and is extremely cost effective even with paying the racking company's installation and labor charges.

 

[kaymccampbell]

I have used the heavier duty steel studs without holes welded or self drillng screwed to the pallet racking to make a wood shed roof. Screwed steel roofing to the studs. 5 years and it still sheds heavy snow like champ.

 

[WMichelsen]

Well, I did embark on this project, and have mostly completed it.
Still need to add latches and door bottom guides. And, maybe add trim to cover up the green corner posts.

Anyway, here are a few phtos of how it came together. There are actually 2 more units behind the camera.
The doors are overlapping suspended rollers with 1" square tube frames.

Overall, I'm pretty happy with it. It's mostly protective, although not fully sealed or small critter proof.
Admittedly, I figured it'd take a couple weekends and maybe $1000. I underestimated the project by about 5x time and 2x money (on top of scavanged materials)

 

[nadogail]

I built a 60 foot fence using load beams from pallet racks for posts. I first trimmed the fittings from both ends of the beams and welded on steel tabs, then set the beams into holes that I filled with concrete. I bolted pressure treated 2X4’s to the posts.

The pickets were nailed to the 2X4 rails.

If I had wanted a shed I would have added more steel to support a roof.

With enough pallet racking and welding rod almost anything is possible.

Pallet Racking and Bed Frames are the ingredients of many of my creations.

 

[cruzer75]

I needed a lean too off the back of my garage for storing stuff like mowers, blowers, and other random stuff that could stay outside but better if covered. I put up a couple sections of racking and screwed metal coragated panelts to it. The uprights and beams had to be pre drilled as the crappy screws i have wouldn't penetrate but other than that it is OK.

 

[ODIS]

My rendition of the pallet rack storage building. The link should take you to my thread that shows the build over several pages to about page 10 or so. Not all about the building but covers what was done.

https://www.garagejournal.com/forum/showthread.php?t=149658&page=7

 

[WMichelsen]

Thanks for the link Odis. I wish I had seen it before my project. Although, I'm not sure it would have changed my approach. My requirements were similar, but also had weather exposure. I sure wish I had your gear and construction talent, also The only thing I may regret on mine is the use of exterior MDF panels. On the doors, they tend to warp/bulge when hit with direct sun. I had not expected that.

Love the cars and club pics. I have an '87 911 Targa that I've had and loved since '91. For 15 years it was my only car. So, it's well exercised with 250K miles. The removable Targa roof came in handy for occasional hauling of stuff. Even brought home a potted 10' Maple tree sticking out the roof from the passenger seat once

Thanks for sharing.
Wayne

 

[californiamilleghia]

Here is another idea