A Guide to Pallet Racking

Estimated reading time: 12 minutes

Key Takeaways:

• Successful racking selection begins with thorough inventory analysis of dimensions, weights, quantities and handling requirements.
• Selective pallet racking provides direct access to every pallet, making it ideal for diverse SKU ranges requiring frequent product rotation.
• Cantilever racking solves storage challenges for long, bulky or irregularly shaped materials unsuitable for standard pallet configurations.
• Drive-in racking maximises storage density by eliminating aisles between rack rows, ideal for large quantities of identical products.
• Longspan shelving bridges the gap between light-duty shelving and heavy pallet racking for hand-loaded items.
• Narrow aisle systems reduce aisle widths to 1,600-1,800mm, increasing pallet positions by 40-50% within existing footprints.
• Mobile racking mounts entire rack structures on motorised bases, achieving 80-100% capacity increase compared to static selective racking.
• Push-back systems use nested carts on inclined rails, enabling pallet storage 2-6 deep with better selectivity than drive-in configurations.
• Wire mesh decking, racking accessories, and load capacity signage are essential accessories enhancing performance and safety.
• Professional installation ensures structural integrity, regulatory compliance and optimal performance.
• Compare suppliers systematically beyond pricing, evaluating quality, installation capabilities, warranty terms and long-term support.
• Design systems accommodating predictable growth through modular configurations and standardised components.

Selecting appropriate pallet racking determines warehouse efficiency, storage capacity and operational costs for years to come. The wrong warehouse storage solutions create bottlenecks, waste valuable floor space and require expensive reconfiguration. This comprehensive buyers' guide examines every critical factor influencing racking selection: inventory characteristics, access requirements, space constraints, budget parameters and future scalability needs, enabling informed decisions matching your specific operational requirements.

Successful racking selection begins with thorough inventory analysis. Document what you're storing: dimensions, weights, quantities and handling requirements. Measure pallet sizes precisely - standard Euro pallets (1200mm x 800mm) and UK pallets (1200mm x 1000mm) require different beam configurations. Non-standard dimensions need custom solutions.

Note: Actual pallet weight capacities depend on pallet construction, load distribution and handling methods.  

Calculate weight distributions across your inventory range. Heaviest items determine beam and upright specifications. Mixing heavy and light goods on the same system risks underutilising capacity or creating safety hazards through overloading lighter sections.

Assess inventory velocity: how frequently you access different products. Fast-moving goods require immediate accessibility. Slow-moving stock can occupy less accessible positions. Seasonal fluctuations affect space requirements - Christmas inventory surges, summer garden product peaks and back-to-school rushes create temporary capacity demands.

Project future growth realistically. Warehouses often reach high capacity utilisation within the first few years of installation. Factor expansion plans into initial specifications. Modular systems accommodate growth better than fixed configurations, though at a higher initial cost.

Selective pallet racking provides direct access to every pallet without moving others, making it ideal for diverse SKU ranges requiring frequent product rotation. This most common warehouse storage solution consists of upright frames and horizontal beams, creating organised storage lanes forklift operators navigate efficiently.

Specify beam capacities matching your heaviest pallets with appropriate safety margins. Standard beam capacities typically range from approximately 900kg to 1,800kg per pair for lighter applications, with heavy-duty options available for heavier loads. Capacity depends on beam length, profile, material thickness and manufacturer specifications. Underspecified beams deflect dangerously under load. Overspecified systems waste budget on unnecessary structural capacity.

Critical specifications:

• Arm length must exceed stored material dimensions by 100-150mm for safe placement
• Arm capacity depends on material weight and centre of gravity - longer arms support less weight than shorter configurations
• Floor anchoring requirements increase with system height and load

Cantilever systems typically cost 50-150% more than equivalent selective racking, but this premium proves justified for materials that simply cannot be stored conventionally. Alternative storage methods - floor stacking or custom fabricated racks - often cost more long-term through space wastage and handling inefficiency.

Drive-in racking maximises storage density by eliminating aisles between rack rows. Forklifts drive directly into rack structures, depositing pallets on rails. This configuration suits operations storing large quantities of identical products: beverage distributors, food wholesalers and cold storage facilities where space costs justify reduced accessibility.

Specify rails and support brackets carefully. Guide rails protect upright frames from forklift contact. Rail spacing must match pallet widths precisely - loose pallets shift dangerously, tight fits prevent smooth placement. Budget for higher ongoing maintenance as confined space operations increase minor damage frequency.

Ideal applications:

• Pick faces for e-commerce operations
• Spare parts storage in manufacturing
• Archive systems for document retention
• Retail stockrooms requiring flexible configuration
• Mixed storage combining palletised goods with smaller items

Longspan systems integrate easily with pallet racking, creating comprehensive warehouse storage solutions. Position longspan picking faces adjacent to pallet reserve storage, enabling efficient restocking without excessive travel distances. This combination optimises both storage density and operational efficiency.

Configure shelving heights matching stored item dimensions. Wasted vertical space between shelves reduces system efficiency. Adjust shelf levels as inventory changes rather than accepting suboptimal configurations.

Narrow aisle systems reduce aisle widths from standard 3,000mm to approximately 1,600-1,800mm, significantly increasing pallet positions within existing footprints. This configuration requires specialist very narrow aisle (VNA) forklifts or guided wire systems, ensuring precision navigation.  

Calculate payback periods considering both equipment investment and space value

Narrow aisle suits established operations with stable product ranges, justifying specialist equipment investment. Growing businesses may find wide aisle systems more adaptable despite lower storage density.

Push-back systems use nested carts on inclined rails, enabling pallet storage 2-6 deep whilst maintaining better selectivity than drive-in configurations. Loading a new pallet pushes existing pallets backwards.

Retrieval brings forward pallets automatically through gravity.

This semi-LIFO system suits operations storing multiple pallets of the same SKU without requiring strict FIFO rotation: non-perishable goods, manufacturing components, and slow-moving stock where exact rotation matters less than space efficiency.

Selection criteria: Push-back works when:

• Storing 2-6 pallets per SKU
• Space efficiency outweighs perfect stock rotation
• Forklift operators can work efficiently with loading/retrieval patterns
• Budget permits higher initial cost versus drive-in alternatives

Specify cart systems carefully. Wheel-based designs require ongoing maintenance; roller systems demand precise installation but prove more reliable long-term. Consider the total cost of ownership rather than just the purchase price.

Note: Costs vary based on specifications, quantity, and supplier. Contact RackZone for specific pricing.  

Load capacity signage on every bay prevents overloading, creating structural failures. Clear labelling ensures operators understand weight limits before placing pallets, maintaining safety margins throughout the system's lifespan.

Column protectors absorb forklift impacts that would otherwise damage load-bearing uprights. Position guards at vulnerable points: aisle ends, corners and high-traffic areas where minor contact incidents occur frequently.

Professional installation ensures structural integrity, HSA compliance, and optimal performance. DIY installation risks:

• Misalignment, creating stability issues
• Inadequate anchoring, compromising safety
• Incorrect component assembly, reducing load capacity

Verify installer credentials:

Relevant experience

• Insurance coverage
• Health and safety compliance
• References from similar projects

Verify compatibility with existing equipment. Beam styles, upright profiles and connection systems vary between manufacturers. Mixing incompatible components creates safety risks and operational problems.

Consider the total cost of ownership:

• Initial purchase
• Installation expenses
• Ongoing maintenance
• Operational efficiency
• System lifespan
• Adaptation costs for future changes

Cheapest upfront options often prove expensive long-term through higher maintenance, shorter lifespan, or operational inefficiency.

Design systems accommodating predictable growth and adaptation. Modular configurations enable capacity expansion without complete reconfiguration. Standardised components facilitate repair and modification using readily available parts.

Leave expansion space in initial layouts. Filling every available square metre prevents future growth within existing facilities. Reserve approximately 15-20% capacity for expansion, enabling organic growth without relocation.

Document your installation thoroughly:

• Layout drawings
• Load capacity specifications
• Component details
• Installation dates
• Maintenance records

Comprehensive documentation facilitates future modifications, ensures proper use and protects liability during inspections.

Review racking performance annually. Monitor:

• Damage incidents and patterns
• Capacity utilisation
• Operational efficiency
• Emerging needs

Proactive assessment identifies issues before they become costly problems, enabling timely adaptations to support changing requirements.

Effective racking selection requires balancing multiple factors: storage requirements, access needs, space constraints, budget parameters, and operational workflows. Professional guidance ensures optimal warehouse storage solutions matching your specific situation rather than generic recommendations.

RackZone supplies comprehensive pallet racking solutions throughout Ireland. Our industrial shelving and warehouse shelving complement pallet systems, creating integrated storage addressing all your requirements.

As Ireland's sole Kimer distributor, we provide European-manufactured systems backed by 50+ years of engineering expertise. Our technical team conducts thorough site assessments, recommends optimal configurations, and manages professional installations, ensuring HSA compliance and efficient operations.

With next-business-day delivery across Ireland when you order before 3 pm, projects progress quickly. Browse our complete storage solutions or contact our specialists for personalised guidance. Call +353 (0)90 9673261 to discuss your warehouse requirements and discover how proper racking selection creates efficient, scalable storage supporting your business growth.