Pallet Racking: A Complete Guide

What Is Pallet Racking?

Pallet racking is a warehouse storage system designed to hold pallets stacked neatly in rows and levels. It is made up of vertical frames and horizontal beams, and is commonly used in warehouses, distribution centres, and industrial spaces.

By storing items vertically, pallet racking helps you make the most of your building’s height, keeping stock organised, easy to locate, and accessible by forklifts.

Compared to traditional shelving, pallet racking offers several advantages:

• Engineered for heavier loads.
• Saves valuable floor space by using building height.
• Forklift accessible for faster retrieval.
• Bespoke adaptability for different pallet sizes, weight loads, and operations.

Shelving may still be useful for smaller, hand-loaded items, but pallet racking is the preferred option for bulk goods.

Learn more about our Pallet Racking solutions.

What Types of Pallet Racking Are There?

There are several different types of pallet racking, each with its own benefits and best use cases:

• Adjustable Pallet Racking (APR): A modular, flexible system where beams can be raised, lowered, or removed as storage needs evolve.

View our Huncote Pallet Racking case study.

• Very Narrow Aisle (VNA): Perfect for maximising capacity, limited floor areas and high ceilings. Accessed with a specialist forklift truck.
• Double Deep: All pallets are stored two units deep reducing the number of access aisles required, operating on a FILO system (first in, last out). This is particularly useful when you have a fast stock turn over and you need to store multiple of the same products. Accessed with a specialist forklift truck.
• Drive-In / Drive-Through: Forklifts drive into this system which can be several bays deep so there is no requirement for aisles operating on a LOFI system (last in, first out). This can still be designed to maximise the use of available ceiling height.

View our Drive-In Racking case study

• Push-Back Racking: Pallets are loaded and pushed back on roller beds. When a pallet is removed from the front the remaining pallets roll forwards. This system is more appropriate for long-term storage as it provides a FILO operation system. Accessible with most types of handling trucks.
• Pallet Flow Racking: A gravity roller system requiring separate load and unload bays, where the pallets are loaded at the higher end and unloaded on the lower opposite side of the bays. This allows for a high turnover FIFO (first in, first out) system and is accessible with most forklifts.
• Cantilever Racking: This system has arms secured on upright frames ideal for unobstructed long storage and managing pallets of varying sizes. Popular for use in building merchants and part of external storage requirements including canopies.

View our Cantilever Racking project case study.

• Shuttle Racking: A forklift loads pallets onto a powered shuttle, which moves stock deeper into the bay. Works for both FIFO and LIFO operations. A standard forklift loads the pallet on the shuttle platform which transports the pallet to the back, unloading it, and returning to the front. This is ideal for deep storage where no specialist driving equipment is required and the battery powered shuttle platform can be transported between bays. This would be appropriate for both FIFO and LIFO operations.
• Custom / Bespoke Systems: Storage Concepts can design tailored racking layouts for unique stock and operational requirements.

How Do You Design an Efficient Pallet Racking System?

At Storage Concepts, we design and install bespoke pallet racking systems to suit your space, stock, and operational needs.

Key factors to consider include:

• Floor area, ceiling height, and fire exits.
• The type of inventory you are storing.
• Aisle widths, determined by handling equipment.
• Integration with other warehouse fit-out elements.

Your order of operations will determine what racking options are available. The sizes of the stock you manage and what vehicle you decide to handle the stock with will dictate the aisle width, racking type, and bay sizes.

With over 40 years of experience, our team ensures your system is safe, efficient, and future-ready.

Speak to our team about a bespoke pallet racking design.

Pallet Racking Installation: What to Expect

Our installation service includes:

• Site survey and CAD design.
• Supply, installation, compliance and load signage.

We typically require:

• Floor plans and/or a site survey.
• Pallet sizes and weights.
• Forklift truck type.
• Operation method (FIFO, FILO, LIFO).
• Expected timescales and other site considerations.

As a guide, approximately 20 bays of pallet racking can be installed in a single day, depending on the system type and project complexity.

How Much Does Pallet Racking Cost?

The cost of pallet racking depends on factors such as system type, size, weight loading, and installation complexity.

As a guide, Storage Concepts works towards around £100 per pallet stored (including installation).

Our turnkey service covers site survey, CAD design, detailed quotation, manufacture, and installation. Each project is managed by a dedicated contracts manager.

Request your free quotation today.

Is Pallet Racking Safe? Key Safety Considerations

Safety is central to every design. Important considerations include:

• Correct load capacities for your pallet weights.
• Bracing and stability for structural security.
• Appropriate aisle spacing for forklift access.
• Training for staff operating equipment.

We provide load signage and support to help you stay compliant.

How Can I Protect My Racking and Staff?

Protective measures and accessories include:

• End barriers and column guards to prevent forklift damage.
• Decking options such as mesh, timber, or pallet support bars.
• Anti-collapse mesh and back stop beams to prevent pallets falling.
• Staff training and clear safety signage throughout your warehouse.

Explore our Cantilever Racking solutions for specialist storage requirements.

Can I Modify or Relocate My Racking Later?

Yes. Pallet racking systems are modular and adjustable, allowing you to:

• Expand your system.
• Reconfigure layouts.
• Relocate racking to new premises.

We also provide reinstallation services to support business growth and relocations.

Do I Need Regular Racking Inspections and Maintenance?

Yes. Regular inspections are essential to ensure safety and compliance.

• Daily and weekly checks: By warehouse staff.
• Monthly checks: By a designated Person Responsible for Racking Safety (PRRS).
• Annual inspections: By a SEMA-approved racking inspector (SARI).

We follow SEMA guidelines and HSE regulations (PUWER). After an inspection, you receive a Red-Amber-Green (RAG) report with clear recommendations.

Learn more about our Pallet Racking Inspections and Repairs.

Why Choose Storage Concepts for Your Pallet Racking Solution?

• Bespoke designs tailored to your requirements.
• End-to-end service: design, supply, installation, compliance.
• Over 40 years of warehouse storage expertise.
• Systems built to SEMA and HSE safety standards.
• Ongoing support with inspections, repairs, and reinstallation.

We are committed to building long-term client relationships, offering advice and support beyond installation.

Get in touch today to start planning your pallet racking solution.