RETA Mühendislik carries out the project design, production, and installation of industrial rack systems for production facilities, bonded warehouses, and distribution centers in Kocaeli under a single responsibility. Founded in 1979, the company manufactures its systems in its own production facility in Manisa Muradiye OIZ and serves Kocaeli through its Marmara regional organization.

Three Main Lines Determining Storage Needs in Kocaeli

The warehouse needs across the province are not uniform, but geographically differentiate into three separate lines.

The automotive sub-industry facilities concentrated around Gebze Organized Industrial Zone and TAYSAD Organized Industrial Zone feed sequential parts to the main industry. The determining factor here is not the pallet capacity, but the picking speed and line-side stock management. In these facilities along the Çayırova and Gebze line, box and bin-based handling systems and mezzanine solutions come to the fore.

The situation changes in the chemical, paint, packaging, and plastics facilities around Dilovası Organized Industrial Zone, IMES Machinery Specialized OIZ, and Gebze Plastic-Makers Organized Industrial Zone. In chemical storage, fire regulations and sprinkler layout limit aisle widths and rack heights right at the design phase. In plastics and machinery manufacturers, the safe handling of injection and press molds weighing tons with cranes requires a separate structural design.

In the port-back bonded warehouses along the Körfez, Derince, and Diliskelesi line, and in the logistics facilities around the Kocaeli Free Zone, the most valuable resource is the clear ceiling height. Multi-tier pallet storage and high-density storage applications are preferred in these facilities. Mixed production facilities along the İzmit, Kartepe, and Başiskele line, as well as food facilities in the Kandıra Food Specialized OIZ, are evaluated separately according to their own conditions.

Rack Design in First-Degree Earthquake Zone

Kocaeli is among the provinces with the highest spectral acceleration values within the scope of the Turkey Building Earthquake Regulation. Under these conditions, a fully loaded pallet rack is not equipment that can be evaluated independently from the building, but is a load-bearing structure in its own right.

In Kocaeli rack system projects, upright sections, anchoring details, vertical and horizontal bracing layouts, and beam connections are dimensioned not only according to vertical load capacity but also according to the seismic parameters of the region. The practical result of this is: a system of the same bay capacity operating without problems in a warehouse in Central Anatolia may require additional bracing, a different upright section, or reinforced anchoring in Kocaeli. For this reason, static calculations are performed separately for each project; no quote is given based on catalog capacity.

Prominent Systems along Gebze, Dilovası, and Körfez Lines

In port-back bonded warehouses and chemical facilities, pallet rack systems are designed according to pallet size, forklift type, and clear height. Euro pallet 800x1200 mm and industrial pallet 1000x1200 mm dimensions require different bay depths and beam spans, while the capacity per bay is calculated according to the weight of the load to be stored.

In automotive sub-industry facilities, carton flow rack systems are used for line-side feeding and order picking. Tier heights are adjusted according to the operator's reach level, and high-turnover parts are placed on the waist-level band to shorten picking time.

In facilities manufacturing plastics and machinery, mold rack systems are designed according to mold weight and crane access height, and drawer-type or fixed-bay solutions are determined according to the frequency of mold changes.

In warehouses where the ceiling height cannot be utilized, mezzanine rack systems increase the existing area to two or three levels. Long materials such as profiles, pipes, and metal sheets are managed with cantilever systems, while facilities with high stock turnover speeds are managed with automated storage AS/RS solutions. All system types are featured on the rack systems page.

Projecting, Production, and Installation Process

The process begins with an on-site exploration at the facility. Floor condition and flatness, column axes, clear ceiling height, sprinkler and lighting layout, forklift type used, and pallet dimensions are recorded. Based on these data, the layout plan and capacity calculation are derived, followed by the preparation of static calculations and technical drawings.

The approved project is produced in the facility in Muradiye OIZ, and installation is carried out on-site by our own teams. Since the warehouse can be worked on by dividing it into phases, the installation can be completed without stopping the operation's shipment and production flow. Upon delivery, load capacity labels and instructions for use are provided. The scope also includes the expansion of existing systems, moving them to another facility, and replacing damaged components.

Kocaeli Rack Systems Exploration and Quotation Process

To get a layout plan and price quote for your facility in Kocaeli, contact us via the contact page. Completed applications in different sectors are featured on our projects page.

Frequently Asked Questions (FAQ) about Kocaeli Rack Systems

How is exploration planned in Kocaeli?

An exploration appointment is scheduled through the Marmara regional organization. A team is dispatched to facilities across the province, from Gebze to Kandıra, and on-site measurements are completed on the same day for most warehouses. After measurement, the layout plan and capacity calculation are prepared and sent to you.

What information should I prepare to get a quote?

Warehouse area and clear ceiling height, pallet dimensions and weight per pallet, target number of bays, forklift type used, and existing layout plan, if any, are sufficient. An initial assessment can be made with this information, and the final quote is established after exploration and static calculations.

How much does the earthquake calculation affect the cost?

Since Kocaeli's seismic parameters may require additional bracing, different upright sections, or reinforced anchoring, the cost may increase compared to a low-risk region. This difference is not an item that can be omitted from the design when compared with the risk of stock loss and occupational accidents that would occur during an earthquake.

Can you move our existing racks to our new warehouse?

After evaluating the type, age, load to be carried, and deformation in the components of the system, dismantling and re-installing it is possible. If the floor strength, ceiling height, or column axes of the new facility are different, reinforcement or partial renewal may be required. The evaluation is made during the exploration.