Extreme Load-Bearing Storage for Rajkot Automotive Plant
Project Overview
An established automotive parts manufacturer operating in the Rajkot industrial zone required a comprehensive overhaul of their warehouse storage infrastructure and factory floor administration areas. The facility produces:
- Heavy cast-iron dies
- Machined jigs
- Precision automotive components
Their existing storage racks were failing under the weight of these components, creating an immediate workplace safety concern. The project scope included replacing the entire warehouse racking system, installing secure workforce lockers for over 200 factory employees, equipping supervisor cabins with durable office furniture, and providing lockable storage for expensive industrial tooling.
Client Requirements
The client's requirements were driven by both safety and operational efficiency:
- 800kg Shelf Capacity: The new racking system had to support a minimum of 800 kilograms per shelf level without any structural deflection, based on the weight of the heaviest cast-iron die sets.
- Workforce Lockers: Lockers for 200+ factory workers across two shifts, featuring a master-key system for supervisor safety inspections while individual workers retained their own keys.
- Industrial-Grade Supervisor Furniture: Office furniture capable of surviving environments with machine grease, metal filings, and heavy vibrations.
- Zero Downtime: Above all, the installation could not shut down or slow the active production lines.
Site Challenges
The factory environment presented three distinct challenges:
- Immediate Safety Risk: Existing lightweight retail-grade racks were buckling with visible deformation. Transitioning inventory to the new system without disrupting production required careful phasing.
- Harsh Industrial Atmosphere: Machine grease vapor, fine metallic dust, and high humidity meant conventional liquid paint would peel within months.
- Uneven Flooring: The warehouse floor had been patched and resurfaced multiple times, making it difficult to level tall racking structures securely.
Planning and Consultation Process
Our industrial products team traveled from Ahmedabad to Rajkot to conduct a thorough site assessment. We documented warehouse dimensions, floor conditions, and the weight/dimensions of every component to be stored (including 300kg cast-iron die sets).
Based on this data, we produced engineered drawings specifying:
- Exact gauge of steel required
- Bracing configuration
- Anchor bolt patterns
- Optimal locker and supervisor cabin placement
The client's plant manager reviewed and approved these drawings before fabrication began.
Furniture Manufactured and Supplied
- Reinforced Slotted Angle Racks: Multi-tier industrial shelving from 14-gauge CRCA steel with double-riveted bracing. Each shelf rated for 800kg.
- Workforce Locker Banks: 200+ multi-tier steel lockers with master-key override, ventilation, and safety equipment hooks.
- Administrative Steel Desks: 8 heavy-duty CRCA steel office tables with welded frames and chemical-resistant worktops.
- Tool Storage Cabinets: 12 lockable steel cabinets with adjustable shelving for precision measuring instruments and cutting tools.
- Steel Workbenches: 6 heavy-gauge steel workbenches with 10mm thick hardwood tops for manual sorting and inspection.
Materials Used
Standard commercial slotted angle racks use 16 or 18-gauge steel, adequate for light inventory. For this application, we specified 14-gauge CRCA steel for all upright pillars and horizontal bracing, providing immense resistance to buckling.
- Bracing: 12-gauge corner plates double-riveted for rigid 90-degree connections.
- Shelving: 16-gauge perforated steel welded to angle-iron frames (perforations allow dust to fall through).
- Pre-treatment: 7-tank chemical process (degreasing, zinc phosphating, passivation).
- Finish: Electrostatic powder coating cured at 180°C to withstand harsh industrial conditions.
Installation and Logistics
Installation in an active factory demands strict safety protocols. Our team coordinated with the factory's safety officer and scheduled work across three consecutive weekends:
- Weekend 1: Removed old failing racks in sections while factory workers transferred inventory.
- Weekend 2: Erected, leveled, and anchored new racking using M12 industrial wedge anchors drilled every 600mm.
- Weekend 3: Installed locker banks and supervisor cabin furniture, completing the transition.
Benefits Delivered
The most immediate benefit was the elimination of structural collapse risk. Additional benefits included:
- 40% Space Increase: Vertical storage density improved, freeing 200 sq ft for a new CNC machining center.
- Improved Shift Flow: Workforce lockers eliminated clutter and secured personal equipment.
- Reduced Tool Loss: Lockable tool cabinets minimized misplacement of expensive precision instruments.
Why Factory-Direct Manufacturing Was Chosen
Retail storage solutions are not engineered for extreme point loads generated by cast-iron components. By engaging us as a direct manufacturer, the client specified the exact steel gauge and load rating required. We engineered, manufactured, and installed the system without distributor margins, resulting in a lower cost per unit with vastly superior structural performance.
Frequently Asked Questions
What is the maximum weight capacity of your industrial slotted angle racks?
Our reinforced slotted angle racks fabricated from 14-gauge CRCA steel with double-riveted corner bracing plates are rated to hold up to 800 kilograms per shelf level. The exact capacity depends on the rack configuration, shelf span, and whether the load is uniformly distributed or concentrated at specific points. We engineer each racking system based on the actual components that will be stored.
Can you install industrial storage in an active factory without shutting down production?
Yes. We regularly execute installations in operational manufacturing facilities. Our installation teams work during planned maintenance windows, weekends, or shift gaps. We coordinate with your production manager to identify periods of lowest factory activity and execute the installation in phases so that existing storage remains accessible throughout the transition.
How does your powder coating perform in harsh industrial environments?
Our electrostatic powder coating is cured at 180 degrees Celsius, creating a finish significantly harder and more chemically resistant than liquid paint. The 7-tank pre-treatment process, which includes zinc phosphating, ensures the coating bonds to the steel at a molecular level. This combination resists machine grease, cutting oil, metallic dust, and the high humidity typical of factory environments in Gujarat.
Do you deliver industrial furniture from Ahmedabad to other cities in Gujarat?
Yes. We manufacture at our Ahmedabad facility and deliver across Gujarat using our own fleet. Recent industrial projects include installations in Rajkot, Surat, Vadodara, and the GIDC industrial estates across the state. For heavy industrial orders, we use flatbed trucks with proper tie-down points to prevent transit damage.
What is the difference between slotted angle racks and pallet racking?
Slotted angle racks are bolt-together shelving systems suited for medium to heavy loads where items are placed and retrieved by hand. They are adjustable in height and configuration. Pallet racking is a heavier system designed for forklift access and pallet-sized loads. For most small to mid-size manufacturing facilities, slotted angle racks offer the right balance of load capacity, flexibility, and cost.
Need Heavy-Duty Industrial Storage?
Do not risk worker safety with undersized retail racks. Get custom-engineered, load-rated industrial storage manufactured and delivered directly from our Ahmedabad factory.
Request Industrial Pricing