Returnable industrial rack system

Abstract

A method for using an industrial shipping rack, including connecting structural members and fasteners to form racks, loading and shipping the racks, unloading the racks, nondestructively disassembling the racks back into structural members and fasteners, and storing the structural members and the fasteners for reuse. Other aspects include receiving industrial/shipping rack designs, locating the racks in shipping containers, placing parcels on the at racks, removing the parcels from the racks, constructing the racks using brackets, converting rack specifications based on inventories, and using thin-walled, metal tubing.

What is claimed is: 
     
         1 . A method for using a modular industrial rack system, comprising:
 operationally connecting at least two structural members with at least one fastener to define at least one rack;   positioning the at least one rack in a shipping container;   loading the at least one rack with cargo to define at least one laden rack;   transporting shipping container with the at least one laden rack to a destination;   unloading the at least one laden rack to yield at least one unladen rack;   disassembling the at least one unladen rack to separate and yield the at least two structural members and the at least one fastener;   storing the at least two structural members and the at least one fastener for reuse; and   inventorying the at least two structural members.   
     
     
         2 . The method of  claim 1 , further comprising the steps of:
 receiving at least one rack design, wherein the at least one rack is based on the at least one rack design; and   continuing the connection of the respective at least two structural members and the at least one respective fastener until the at least one rack design is fully realized.   
     
     
         3 . The method of  claim 1 , further comprising the steps of:
 receiving at least one rack with at least one damaged portion, wherein the at least one damaged portion is selected from the group comprising at least one structural member, at least one fastener, and combinations thereof;   removing the at least one damaged portion; and   replacing the at least one damaged portion with at least one repair portion, wherein the at least one repair portion is selected from the group comprising at least one structural member, at least one fastener, and combinations thereof.   
     
     
         4 . The method of  claim 1 , wherein the modular rack system is further constructed using at least one bracket. 
     
     
         5 . The method of  claim 1 , wherein the at least one structural member is thin-walled, 11-gauge metal tubing. 
     
     
         6 . A method for constructing and deconstructing modular, industrial racks, comprising the steps of:
 operationally connecting at least one structural member, at least one bracket, and at least one fastener to form at least one industrial rack unit, wherein the at least one structural member is constructed of thin-walled metal tubing;   continuing the connecting step until the rack unit complete;   positioning the at least one industrial rack unit in a shipping container; and   nondestructively disassembling the at least one rack unit back into the at least one structural member, the at least one bracket, and the at least one fastener, wherein the at least one structural member, the at least one bracket, and the at least one fasteners may continue to be reconstructed into rack units.   
     
     
         7 . The method  claim 6 , further comprising the step of:
 storing the at least one structural members and the at least one fastener for reuse.   
     
     
         8 . The method  claim 6 , further comprising the step of:
 measuring cargo to be shipped to determine cargo dimensions, wherein the rack unit has a cargo volume that snugly accommodates the cargo dimensions.   
     
     
         9 . The method  claim 6 , further comprising the step of:
 repairing a damaged rack unit by replacing at least one damaged portion on site, further comprising the steps of:
 disconnecting the at least one damaged portion from the rest of the rack unit; 
 removing the at least one damaged portion to define at least one gap; 
 inserting at least one undamaged portion into the at least one gap; and 
 operationally connecting the undamaged portion to the rest of the rack unit. 
   
     
     
         10 . The method  claim 6 , further comprising the step of:
 receiving at least one rack schematic.   
     
     
         11 . The method  claim 6 , further comprising the step of:
 loading the at least one industrial rack unit;   shipping the at least one shipping container to a predetermined destination; and   unloading the at least one industrial rack unit.   
     
     
         12 . The method  claim 6 , further comprising the step of:
 placing at least one parcel on the at least one rack unit; and   removing the at least one parcel from the at least one rack unit.   
     
     
         13 . The method  claim 6 , further comprising the step of:
 converting the at least one rack schematic specifications based on at least one inventory of the at least one structural member, the at least one bracket, and the at least one fastener.   
     
     
         14 . A reusable industrial and shipping rack system, comprising:
 a plurality of structural members;   a plurality of respective fasteners, each respective fastener configured to operationally connect to a respective structural member; and   a plurality of brackets, each respective bracket configured to interface between a respective one structural member and a respective fastener;   wherein each respective structural member, fastener, and bracket may be repeatedly removably connected together to assemble a reusable industrial shipping rack;   wherein the reusable industrial shipping rack may be nondestructively broken down into respective structural members, fasteners, and brackets;   wherein the nondestructively broken down components of the reusable industrial shipping rack may be reconnected to assembly at least another reusable industrial shipping rack; and   wherein at least two structural members are free to move relative to one another when connected together.   
     
     
         15 . The system of  claim 11 , wherein the reusable industrial shipping rack is selected from a group consisting of the same reusable rack design, a different reusable rack design, and a combination thereof. 
     
     
         16 . The system of  claim 11 , wherein the reusable industrial shipping rack is configured to be placed in a shipping container. 
     
     
         17 . The system of  claim 11 , wherein at least one respective bracket allows for slippage of connected structural members relative to one another. 
     
     
         18 . The system of  claim 11 , w herein the reusable industrial shipping rack is configurable with at least one lifting zone. 
     
     
         19 . The system of  claim 11 , wherein the at least one lifting zone further comprises:
 at least one lifting portion, wherein the at least one lifting portion is capable of supporting the reusable industrial shipping rack; and   at least one lifting aperture forming the entrance to the at least one lifting portion.   
     
     
         20 . The system of  claim 11 , wherein at least one respective bracket allows for pivoting of connected structural members relative to one another.