Steel rebar in 12-meter lengths presents one of the most physically demanding storage challenges in any metals distribution center or prefabrication yard. A single bundle of 12 m rebar can exceed 5 tons, and the bar’s flexibility over that span causes sagging that degrades the material, complicates counting, and makes extraction of individual bars a hazardous manual operation. The Herochu double-sided cantilever rack for 12 m steel rebar storage addresses these conditions with a structural and operational design engineered specifically for long, heavy, flexible payloads.
The 12-Meter Rebar Storage Problem
Rebar is not a rigid profile. A 12 m length of #6 rebar (approximately 19 mm diameter) will deflect under its own weight when supported only at the endpoints. When stored in bundles on conventional fixed cantilever arms, this deflection concentrates stress on the outer bars at the bundle edges, causing permanent bowing that may exceed ASTM A615 tolerances for straightness. Bars that arrive within tolerance can leave storage out of tolerance.
The secondary problem is access. In a conventional rack, reaching a specific bundle grade or diameter requires a forklift to travel the full rack length, lift the target bundle clear of adjacent bundles, and reverse out — all within a turning aisle that consumes floor area equal to the rack itself. The Herochu telescopic cantilever rack eliminates the turning aisle by extending only the target tier directly toward the forklift operator.
Double-Sided Architecture for Maximum Throughput
The Herochu double-sided configuration provides independent storage tiers on both faces of the rack. This is not a mirror-image layout where both sides store the same material — each side carries different rebar grades, diameters, or bundle configurations. The structural advantage of the double-sided design lies in load balancing: when a 5,000 kg bundle is deposited on the front tier, the opposing rear tier can carry a counterbalancing load that stabilizes the entire column assembly during the extension cycle.
| Model | Pipe Length | Max Load per Level | Number of Layers | Clear Space |
|---|---|---|---|---|
| HC-G12065 | 12,000 mm | 5,000 kg | 6 (customized) | 600 mm (customized) |
The HC-G12065 is the flagship configuration for 12 m rebar. Its 12,000 mm pipe length accommodates the full stock length without overhang, and the 5,000 kg per-level capacity handles the heaviest mill bundles. The six-layer arrangement, when deployed on both sides, provides 12 independent compartments — sufficient to segregate rebar by grade (A615 Grade 40, 60, 75, 80), diameter (10 mm through 43 mm), and supplier lot for traceability.
Q235B High-Strength Steel Frame with Dual-Beam Crossbar
At 5,000 kg per level, the structural demands on the rack frame increase substantially compared to lighter-duty cantilever systems. The Herochu HC-G12065 uses a Q235B high-strength steel frame with a dual-beam crossbar design. The dual-beam configuration places two horizontal cross-members between the upright columns at each tier level, creating a load path that distributes the 5,000 kg across both columns rather than concentrating it on a single attachment point.
This design decision has a direct consequence on rack longevity. In single-beam configurations, the beam-to-column connection absorbs the full cantilever moment generated by the payload. Over thousands of load cycles, this connection develops fatigue cracking at the weld toe — the junction between the beam flange and the column face. The Herochu dual-beam design halves the moment per connection, extending the fatigue life of the critical structural joint by a factor that the Herochu engineering team validates through Simsolid finite element analysis during the design phase for each custom configuration.
Independent Compartments per Tier
Rebar storage fails when grades and diameters mix. A bundle of 12 mm bars stored adjacent to 25 mm bars creates a height differential that causes the smaller bars to migrate into the gaps between larger bundles during vibration — from forklift travel, crane operation, or seismic activity. Once mixed, the only remedy is manual sorting, which costs labor time and introduces the risk of misidentification at the fabrication station.
The Herochu independent compartment design addresses this at the physical level. Each tier on each side of the rack is a discrete storage cell with its own base tray and side guides. A bundle deposited in compartment A-3 cannot migrate into compartment A-2 or B-3. The base tray is fabricated from formed steel sheet with a 2 mm thickness, providing a smooth surface that prevents rebar surface scarring during loading and retrieval. For epoxy-coated rebar — where surface damage exposes the underlying steel to corrosion — this tray surface is a functional requirement, not a cosmetic detail.
Telescopic Extension for Forklift and Crane Access
The telescopic mechanism on the HC-G12065 uses a dual-side mechanical assistance system. When an operator initiates extension — via hand crank or electric motor — the tier slides outward on guide rails mounted to the rack columns. The guide rails are manufactured from galvanized steel with machined contact surfaces, providing low-friction travel that requires minimal drive force even at full 5,000 kg payload.
The extended position places the bundle at a reach that aligns with standard forklift fork penetration depth. The forklift operator drives forward, inserts forks under the bundle, lifts clear, and reverses. No turning within the rack aisle is required because the turning aisle has been eliminated. For operations using overhead cranes, the tier extension height is configured to position the bundle within the crane’s lifting envelope, allowing direct hook engagement without a forklift intermediary.
When the operator completes the retrieval and retracts the tier, the rack returns to its compact footprint. A six-layer, double-sided configuration holding 12 bundles of 5,000 kg each — 60 tons total payload — occupies a floor area that a conventional rack would need just for its turning aisle.
Dual-Side Mechanical Assistance and Drive Options
The HC-G12065 offers both hand-cranked and electric drive configurations. The hand-cranked system uses a gear-and-rack transmission with a worm gear self-locking ratio, so the tier holds position when the crank is released. At 5,000 kg payload, the gear ratio is selected to keep handle force within practical limits for a single operator — typically below 20 kg of input force.
The electric drive system adds a geared motor with integrated brake and dual limit switches. The brake engages automatically when the motor stops, providing redundant locking alongside the mechanical self-locking gear train. The limit switches define the travel endpoints: full extension and full retraction. Between these endpoints, the operator can stop the tier at any intermediate position by releasing the control button.
Surface Treatment for Outdoor and Indoor Environments
Rebar storage often occurs in partially exposed environments — open-walled warehouses, material yards with canopy covers, or fully outdoor storage zones. The Herochu HC-G12065 standard configuration includes an electrostatic powder-coated finish applied to all structural members. The coating system consists of a phosphate conversion pretreatment, a primed base coat, and a polyester topcoat with UV stabilizers. This three-layer system provides corrosion resistance suitable for environments with intermittent moisture exposure.
For installations in coastal areas or fully outdoor yards with salt-laden air, the cantilever arms are available in galvanized steel. Hot-dip galvanizing applies a zinc coating that sacrifices itself to protect the underlying steel substrate, providing corrosion protection that does not depend on coating integrity — critical in environments where forklift impact may damage organic coatings.
Customization for Rebar Yard Operations
Herochu configures the HC-G12065 to the specific operating parameters of the rebar yard. Customizable elements include:
- Tier count: Six layers standard; adjustable from 4 to 8 layers based on ceiling height and forklift maximum lift height.
- Clear space: 600 mm standard; expandable to 1,200 mm for yards handling oversized bundle configurations.
- Load per level: 5,000 kg standard; the frame can be engineered for 6,000 kg per level for yards handling specialized heavy rebar bundles.
- Compartment configuration: Standard single-bundle compartments; multi-bundle compartments available for yards that store smaller-diameter rebar in multi-bundle groups.
- Drive selection: Hand-cranked for yards with intermittent retrieval; electric for high-throughput operations feeding continuous fabrication lines.
Pre-Shipment Validation
Every HC-G12065 rack undergoes a pre-shipment load test at the Herochu manufacturing facility. The test applies 1.25 times the rated load to each tier and measures deflection at the arm tip. The deflection must remain within the design envelope — typically less than L/200 of the arm length — and must recover fully when the test load is removed. This validation confirms that the as-manufactured frame meets the rated capacity and that no weldment or connection has yielded during fabrication handling.
The test report, including deflection measurements and recovery data, accompanies each rack shipment. For installations requiring CE or ISO compliance documentation, the test report serves as the manufacturing evidence referenced in the conformity assessment.
Application Scope
The HC-G12065 is deployed in concrete rebar prefabrication yards, steel distribution centers handling long bar stock, and precast concrete plants where rebar cages are assembled near the storage point. Wherever 12 m rebar is received, stored, and dispatched in tonnage quantities, the double-sided telescopic cantilever rack provides the load capacity, compartment segregation, and access efficiency that the operation requires.
