The Ultimate Pallet Racking Guide

Take a look, and you’ll notice that pallet racking is all around us. If you’ve ever been to Costco or Home Depot, you might have noticed it. Or maybe you’ve seen a distribution center. It’s a vital component of our supply chain ecosystem and the material handling industry.

The importance of pallet racking for warehouse management cannot be overstated. It helps to optimize storage space, improve inventory management, and enhance the overall efficiency of warehouse operations.

Speedrack West is a premier distributor of new and used pallet racking, cantilever racking, and industrial storage products. If you’re newer to this topic and other warehouse solutions, we created this comprehensive guide for you.

Table of Contents 

I. What is pallet racking?
II. Choosing a Pallet Rack System
III. Installation
IV. Inspection and Maintenance
V. Safety Considerations
VI. Conclusion

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I. What is pallet racking?

Pallet racking is a common storage solution used in warehouses and other industrial settings to store palletized goods. It refers to a system of industrial racks and shelves designed to support pallets of various sizes and weights. This system helps make pallet storage and retrieval efficient. 

Below, we will explore the different types of racking systems. We’ll also cover the factors to consider when choosing the right system, installation, inspection, maintenance, and safety considerations.

Types of Pallet Racking Systems

There are many types of pallet racking systems and it’s vital to know which one to choose to carry out your warehouse management goals.

Selective Pallet Racking

Selective pallet racking is the most common type of system. It consists of vertical upright frames, horizontal beams, and metal or wire decking (aka, pallet rack shelving).

Pallets are stored on the support beams, which can be adjusted to accommodate different pallet sizes and weights. The upright frames are instantly recognizable by the teardrop-shaped holes, which is the most popular of many styles. Uprights are often green in color and the cross beams are often orange.

A selective rack is an ideal solution for warehouses that store a variety of products with different turnover rates, as it allows easy access to all pallets and is highly versatile. In many cases it is simple to add on additional bays of pallet racking as your storage needs increase. By far, they are the most popular type of racking in North America and several other regions.

One of the main advantages of selective pallet racking is that it provides high selectivity and accessibility to all pallets. However, it is not the most space-efficient type of system and may not be ideal for high-density storage.

(Learn more about Selective Pallet Racking.)

Cantilever Racking

Cantilever racking is a storage system that is designed to store long and bulky items, such as lumber, piping, and furniture. The system features a series of vertically oriented columns with horizontal arms extending from them. Items are stored on the horizontal arms, which can be adjusted to accommodate items of different sizes.

The main benefit of cantilever racking is that it allows for the safe and efficient storage of long and bulky items, which can be difficult to store in traditional racking systems. The open design of the system also allows for easy access to stored items, making it ideal for businesses that need to frequently retrieve and restock items. Additionally, the system can be customized to fit the specific needs of a business, with options for different arm lengths and weight capacities.

(Learn more about Cantilever Racking.)

Drive-In & Drive-Through Pallet Racking

Drive-in pallet racking is designed for high-density storage of homogeneous products with low turnover rates. (That is, these products are identical in size, quality, and quantity. Think seasonal items, high-ticket electronics, specialty foods, luxury items, and niche products.)

It features a series of lanes with rails that allow pallets to be stored and retrieved by using a forklift truck that drives into the rack structure. This type of system maximizes storage capacity by reducing the number of aisles required for fork trucks to access.

The main advantage of drive-in pallet racking is its high storage density, making it ideal for warehouses with limited space. However, it has limited accessibility. These systems have tight spaces and require excellent forklift operators to minimize the damage to the rack structure.

Drive-Through pallet racking is similar to Drive-in, however it is set up so forklift drivers can drive completely through the rack system. This allows FIFO access to the goods as the product can be loaded on one end and unloaded on the other end.

(Learn more about Drive-In Pallet Racking.)

Push-Back Pallet Racking

A push-back pallet rack is a system in which standard pallets are stored on a series of nested carts that move along inclined rails. When a pallet is loaded onto the front cart, it pushes the next cart back, allowing for multiple pallets to be stored on each level. This type of system is ideal for high-density storage of multiple SKUs with medium to high turnover rates. This can be set up with back-to-back rows.

Push-back systems provide high storage density and selectivity while minimizing the number of aisles required for forklift access. They are a LIFO storage system: Last In First Out. However, they may not be suitable for storing large or heavy items, and the carts may require periodic maintenance.

(Learn more about Push-back pallet racking.)

Double-Deep Pallet Racking

Double-deep pallet racking is similar to selective pallet racking, but pallets are stored two deep on each level. This type of system provides a balance between high storage density and high selectivity. It is ideal for warehouses that store a moderate number of SKUs with medium to high turnover rates.

Double-deep systems provide higher storage density than selective racking while maintaining a moderate level of selectivity. However, it requires specialized forklifts, and it may not be suitable for storing large or heavy items.

II. Choosing a Pallet Racking System

When considering the right pallet rack system for your needs, one important factor to consider is the tradeoff between selectivity and density. Selectivity refers to how easily accessible each pallet is. In a “selective pallet rack,” every pallet is easily accessible without any other pallets blocking the way. This makes it a highly selective option. However, the downside is that selective racks require more aisle space, which reduces storage density. 

On the other hand, push-back racks have lower selectivity (with a few pallets in front of the one you need to access), but they require less aisle space and offer higher storage density. Each system has its own way of balancing selectivity and storage density to suit different needs.

Warehouse Space and Layout

When it comes to selecting the right racking system for your business, it’s essential to partner with an experienced racking vendor. Working with an inexperienced vendor may result in recommendations that are not tailored to your unique application needs. Therefore, it’s crucial to ensure that the individuals providing you with racking quotes have extensive experience and are taking into account the various factors unique to your business. Rest assured that with an experienced racking partner by your side, you’ll be able to select the ideal racking system to meet your specific requirements.

Ensuring optimal use of warehouse space is a critical factor for businesses to maintain efficiency in their operations. To achieve this, several crucial elements must be considered, such as the pallet size, product size, weight, dimensional consistency, concrete floor thickness, building height, product flammability, adequacy of fire sprinkler systems,flow of products through the warehouse, number of SKU’s, and turnover rate of SKU’s. 

Taking these factors into account enables a business to design a functional and practical layout for their warehouse, optimizing space utilization, maximizes safety, and facilitating a smooth flow of goods throughout the facility. As such, a well-designed warehouse layout can significantly contribute to the overall success of a business by improving productivity and reducing operational costs. 

If you’re in the process of planning your warehouse space and layout, having a CAD drawing can be incredibly helpful. That’s why we suggest checking out our CAD drawings page, where you can find resources to assist you in creating the most efficient and effective layout for your warehouse.

(Learn more about Warehouse Space and Layout.)

Weight and Size of Products

Another critical factor to consider when choosing a racking system is the weight and size of the products being stored. Heavy products require robust racking systems that can withstand the weight without collapsing, while larger products may require customized racking systems. Some of the key considerations when choosing a pallet racking system based on the weight and size of products include:

Storage Capacity
The type of racking system selected should have sufficient capacity to handle the weight of the products being stored.

Storage Density
When it comes to pallet racking, storage density is an important consideration. Here are a few factors that should be taken into account when considering storage density:

1. 1. Pallet Size: The size and weight of the pallets that will be stored in the racking system should be carefully considered. This will help determine the size and spacing of the racking components needed to accommodate the pallets.
   2. Aisle Width: The width of the aisles between the racking units is critical in determining storage density. Narrower aisles can allow for more storage density but require specialized equipment, while wider aisles provide more room for maneuverability but decrease storage density.
   3. Height of Racking: The height of the racking system can also affect storage density. Higher racking systems can provide more storage space but require additional safety features such as wire mesh decks, seismic bracing, and extra anchoring to ensure stability.
   4. Inventory Management System: An effective inventory management system can help maximize storage density by reducing the amount of wasted space due to overstocking or understocking.

Overall, when considering storage density with pallet racking, it’s essential to strike a balance between maximizing storage space and ensuring safe and efficient access to inventory.

Inventory Management

Inventory management is another critical factor to consider when choosing a pallet racking system. A good racking system should be able to accommodate different types of products and allow for easy product identification and retrieval. Some of the key considerations when choosing a racking system based on inventory management include:

• Storage efficiency: The type of system selected should be efficient in terms of storage. Pallet flow rack, for example, is an efficient storage system that allows for the easy rotation of products while maintaining first-in, first-out (FIFO) product flow.
• Storage flexibility: The type of system selected should be flexible enough to accommodate changes in inventory. Selective pallet racking, for example, allows for easy product movement and reorganization. (By the way, this is one reason why it’s the go-to multi-level storage system.)

Inventory management is another critical factor to consider when choosing a pallet racking system. A good racking system should be able to accommodate different types of products and allow for easy product identification and retrieval. Some of the key considerations when choosing a racking system based on inventory management include:

• Storage efficiency: The type of system selected should be efficient in terms of storage. Pallet flow rack, for example, is an efficient storage system that allows for the easy rotation of products while maintaining first-in, first-out (FIFO) product flow.
• Storage flexibility: The type of system selected should be flexible enough to accommodate changes in inventory. Selective pallet racking, for example, allows for easy product movement and reorganization.

Cost of Pallet Racking

Warehouse pallet racking pricing is an important consideration when choosing a system. First, it is essential to determine the budget for the project, including the cost of materials, installation, and maintenance. Pallet racking systems can vary significantly in price depending on the type, size, and features. It is important to balance cost with functionality and durability to make the best investment for your warehouse.

The rack capacity is one of the key factors that affect the cost of a system. The higher the rack capacity, the more expensive the system will be. However, it is important to choose a pallet racking system that can accommodate the weight and size of your products to ensure safe and efficient storage.

Pallet rack design can also affect the cost of the system. The design should be based on the specific requirements of your warehouse, including the available space and product storage needs. A customized racking system may cost more than a standard system, but it can provide better functionality and efficiency in the long run.

Other factors that can impact the cost of a good system include the manufacturer, installation cost, and maintenance expenses. It is important to research and compare different pallet racking systems and manufacturers to find the best value for your budget.

(Learn more about Warehouse Optimization and Inventory Management.)

III. Installation 

Pallet Racking Installation

Proper installation of pallet racks is crucial to ensure their safety and longevity. Installation should only be done by trained professionals who have experience with the specific type of system being installed. The installation process should follow the manufacturer’s guidelines and safety standards.

The installation process should begin with a walkthrough by the installer to make a thorough assessment of the warehouse space and planned layout. The warehouse layout should be planned to maximize the use of available space and ensure safe and efficient material handling. And as mentioned before, the installation team should also take into account the weight and size of the products being stored to ensure that the system is properly designed to handle the load.

(Learn more about Pallet Rack Installation)

IV. Inspection and Maintenance 

Pallet Racking Inspection

Regular inspection of racking systems is important to ensure their safety and performance. Inspections should be done by trained personnel who understand the specific type of pallet racking system being inspected. Although it’s recommended to have rack inspections conducted by trained personnel, it’s important to remind all employees to notify management or the safety department immediately of any visible rack damage. Doing so allows for prompt assessment and replacement of damaged racking, which should be a safety concern. 

Don’t wait for an annual inspection to identify and replace damaged parts – everyone in the workplace plays a crucial role in ensuring the safety of the racking system. By working together and being vigilant, you can maintain a safe and secure work environment by conducting inspections on a regular basis. Racks should be inspected at least once a year, or more frequently if there is a high amount of activity in the area.

During the inspection process, the pallet racks should be checked for any damage or signs of wear and tear. Any damaged or broken components should be replaced immediately to ensure the safety of the system.

Inspections should also include a review of the safety items that should be added to the racking system to prevent additional damage. Also, ensure that the weight of the products being stored on the racking is within the racks designed capacity.

Pallet Racking Maintenance

Regular maintenance of racking systems is important to ensure their longevity and performance. Any damaged or worn components should be replaced immediately to prevent further damage to the system.

Though technically once your beams and upright frames are set, there is no maintenance. These are permanent structures. However, it’s what happens to the rack that may need maintenance or repair. 

V. Safety Considerations 

Importance of Pallet Rack Safety

Safety is paramount in any warehouse, and pallet racks are no exception. Ensuring the safety of employees, products, and equipment is critical to the success of any business. For example, a well-designed system should provide a safe and secure environment for workers to operate in, while also minimizing the risk of damage to products and equipment.

Safety Regulations and Standards

There are a number of safety regulations and standards that apply to pallet rack systems, and it’s important to be aware of them when selecting and installing a system. The Occupational Safety and Health Administration (OSHA) has specific regulations regarding the design, installation, and use of pallet racking systems, as well as guidelines for inspections and maintenance.

OSHA’s regulations require that all pallet racking systems be designed and installed in accordance with the manufacturer’s instructions or with the guidance of a qualified person with extensive knowledge. Additionally, OSHA requires that the pallet racking system be capable of supporting the weight of the materials being stored and that the system be secured to prevent tipping or collapse.

Also, OSHA mandates that pallet racking systems be inspected regularly to ensure that they are in good condition and that any damage or defects are repaired promptly. Employees who work with or near pallet racking systems must be trained on safe operating procedures, such as how to load and unload materials properly and how to identify and report any hazards or defects in the system.

Overall, OSHA’s regulations for pallet racking systems are intended to ensure that workplaces are safe for employees and that the risk of accidents and injuries is minimized.

In addition to OSHA regulations, there are a number of industry standards and guidelines that govern the use of pallet racks. The Rack Manufacturers Institute (RMI) publishes a set of guidelines known as the “Specification for the Design, Testing and Utilization of Industrial Steel Storage Racks”. This specification provides guidance on the design, installation, and use of pallet racking systems in industrial settings.

The RMI specification includes detailed requirements for rack design, including the load capacity, column and beam dimensions, and bracing requirements. It also covers installation guidelines, including floor anchorage, plumb and level installation, and clearance requirements. The specification also provides guidance on maintenance and repair of the racking system.

The American Society of Mechanical Engineers (ASME) has a standard for the design, testing, and inspection of steel storage racks, which is known as ASME B30.16. This standard provides guidelines for the design, manufacture, testing, installation, maintenance, inspection, and operation of steel storage racks.

ASME B30.16 covers various types of steel storage racks, including cantilever racks, drive-in and drive-through racks, and pallet racks. The standard includes detailed requirements for rack design, including load capacity, beam capacity, column dimensions, and bracing requirements. It also covers installation guidelines, including floor anchorage, plumb and level installation, and clearance requirements.

Additionally, ASME B30.16 provides guidance on the inspection, maintenance, and repair of the racking system to ensure its safe and continued use. If all of this sounds like a lot, don’t worry. We have warehouse racking experts at Speedrack West who have helped countless customers simplify the process so they can focus on running their businesses.

Safety Features and Accessories

To ensure the safety of workers and products, rack systems should be equipped with a range of safety features and accessories. These can include:

• Wire Decking is the most common safety item for pallet racks, as it helps prevent small items from falling to the ground.
• Column Guards are installed at the base of each column to prevent damage from forklifts and other equipment. They absorb or deflect the impact of a collision and help prevent damage to the racking system. 
• Bollard posts are designed to protect the rack from impact and prevent forklift damage. These posts are installed at the base or corners of the rack in high-traffic areas and provide a barrier between the racking system and the equipment. 
• Guard Rails can be put up to protect racking, conveyor belts, or other equipment.
• Pallet Rack Guards, also called End of Aisle Guards, can be installed to protect your pallet rack ends.
• Backstop Beams help forklift operators properly place a pallet on the beams.
• Safety Nets can be used to protect your people from falling products.
• Load Stop Screens, or “Rack Backs”, are heavy-duty metal wire backing screens that prevent pallets or products from falling off the back side of the rack. They are a heavy-duty alternative to safety straps or nets.
• Beam Safety Drop Pins (aka, J Bolts) are used to reduce the risk of a beam becoming accidentally disconnected. 
• Safety Clips help prevent beams from becoming disconnected. They are similar to safety drop pins, but safety clips are designed for specific types of beams. 
• Row Spacers are important because it helps racks keep their shape or space footprint.
• Capacity Stickers show the maximum amount of weight that can be stored on each beam level.

(Learn more about Pallet Rack Safety.)