How to Choose the Right Pallet Racking for Your Warehouse

Before comparing pallet racking systems, take a look at what needs to go on them. Pallet dimensions, loaded weights and available space are the starting points for choosing a system that works in your warehouse.

Next, consider how stock moves through the building and whether you’re starting from scratch or extending existing racking.

Quick Summary

  • Check your pallet sizes, maximum loaded weights and the number of positions required.
  • Plan around usable space and the equipment that needs to move through it.
  • Choose a layout that suits how often you need access to individual pallets.
  • Identify any existing racking before ordering extra components.
  • Allow for future changes, not just the lowest initial price.

Start With the Pallets You’re Storing

When someone asks 3JC about pallet racking, Will’s first questions are about pallet size, loaded weight and the space available. He says customers sometimes overlook pallet dimensions and weights.

Before requesting a recommendation, make a note of:

  • Pallet size: width, depth and height once loaded.
  • Maximum loaded weight: not just the weight of an empty pallet.
  • Quantity: the number of pallet positions you need.
  • Variations: whether some pallets are taller, heavier or unusually shaped.

Taller loads may affect beam-level spacing, while heavier loads require a suitably assessed configuration. Never assume similar-looking bays have the same capacity.

Work Out How Much Space Is Usable

Doors, columns, loading areas and access routes all affect where racking can go.

Sketch the building dimensions, fixed obstructions and areas that must remain clear. Include usable height: a tall building doesn’t necessarily offer the same height for storage.

Don’t maximise pallet positions at the expense of safe vehicle and staff access. The HSE’s warehousing and storage guidance provides useful background on those wider considerations.

Think About How People Access the Stock

If staff retrieve many different products throughout the day, direct access to each pallet may be essential.

A business storing larger quantities of similar stock for longer periods may prefer denser storage.

Conventional selective pallet racking gives direct access to each pallet position. Other arrangements involve different trade-offs between capacity and access. Our guide to warehouse racking types explains the main options.

Ask yourself: How often do we need each pallet, and what equipment will retrieve it?

Extending Existing Racking? Identify It First

If you’re adding beams or frames, don’t judge compatibility by appearance. Manufacturers can use similar colours but different connections.

Will says a photograph is a useful starting point when a customer isn’t sure what they have.

A close-up of the beam-to-upright connection helps; beam box-section dimensions and frame width may also be needed.

The Pallet Racking Identification Guide explains what to photograph, and our Measuring Pallet Racking guide covers the measurements. Any proposed alteration should be assessed for compatibility, loading and stability rather than treated as a simple parts swap. SEMA’s technical bulletins provide further industry guidance.

Consider What Might Change

A suitable system should meet today’s needs without making tomorrow’s changes unnecessarily difficult. You may need more positions, different stock or replacement parts.

Look beyond the initial price. Delivery, suitable installation, later changes and access to spares can affect the overall value. Will notes that inspected, fit-for-purpose used racking can be a budget-friendly option, while new racking may be preferred for appearance or easier access to spare parts. Neither is automatically the better choice. Our Used Racking vs New guide explores that decision separately.

What to Have Ready When You Contact 3JC

You don’t need to arrive knowing the name of the system you want. Start with your pallet dimensions and loaded weights, the number of positions required and a sketch or measurements of the space. Mention the handling equipment you use and send photographs if you’re extending existing racking.

3JC can then discuss the pallet racking range, explain what still needs checking and help you narrow the options. Contact the warehouse team at 3JC when you are ready to talk through your requirements.

Frequently Asked Questions

Do I need to choose a racking type before speaking to 3JC?

No. Explain what you need to store and how your warehouse operates. A supplier can then discuss suitable options with you.

Can I keep using my current forklift with a different layout?

Possibly, but don’t assume it. The truck’s operating and lifting requirements need to be considered alongside aisle widths, racking height and the proposed layout.

What if I store pallets of several different sizes or weights?

Share the range of dimensions and the maximum loads, rather than an average. The intended configuration needs to be assessed for all the pallets you plan to store.

Do I need a detailed floor plan before asking for advice?

Not necessarily. Accurate basic dimensions and photographs are a useful starting point, although a final layout will need more detailed information and appropriate assessment.