The use of pallet racking in warehouses is very common, and the specifications and dimensions need to be developed according to the size of the warehouse area and the size of the pallets. pallet racking are also the most popular type, with advantages such as low cost, high storage capacity, safety and reliability, easy assembly and disassembly, and convenient management. They are suitable for manual access and require corresponding loading and unloading machinery when storing goods at a high level. Cross beam shelves have a simple and beautiful overall appearance, high safety factor, and save space. They are widely used in warehouses. As long as proper standardization is paid attention to during use, the efficiency of the racking can be fully utilized and maximized.
1. pallet racking structure is simple, safe and reliable, and can be adjusted and combined freely. The inbound and outbound storage is not limited by the order of items. Widely used in storage modes such as pallet storage and forklift access.
2. The column pieces of the pallet shelf are connected by the columns, cross braces and slant support with bolts. The shelf frame is composed of column pieces and C-shaped welded beams, which are fixed with safety pins and have a simple and reliable structure. Each layer can be freely adjusted up and down with a step distance of 75mm or 50mm.
3. The pallet rack can determine the layer load requirements according to the size of the columns and beams, and has the characteristics of high inertia, strong layer load capacity, and strong impact resistance. The maximum layer load per layer can reach 5000kg under relative design.
4. The height of a single column on a pallet rack can reach up to 12 meters, and the plasticity of the pallet rack is very large.
5. pallet racking system can effectively increase the storage height of warehouses and improve the space utilization rate of warehouses. Suitable for storing various types of goods.
6. The appearance of the pallet rack is safer, and it can prevent forklift collisions by adding column foot guards and anti-collision bars. For safer layer loading, auxiliary facilities such as beam supports, racking, and mesh spans can also be installed on the beams.
7. pallet racking have low cost, are easy to install and operate, and are easy to locate. They are suitable for any handling tool and are therefore the most widely used type of shelf.
8. pallet racking can also be equipped with racking, including mesh racking. In order to use trays of different sizes.
Pallet racking frames are the vertical structural components that form the backbone of a pallet racking system. They support the horizontal beams upon which palletized loads are stored.
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Step1: Choose Beam Type & Specifications
Beam Types:
Type Best For Capacity Range Pros/Cons
Roll-Formed Light/medium duty (≤10k lbs) 1,000–8,000 lbs/pair ✅ Low cost, easy install
❌ Lower impact resistance
Structural Heavy-duty (>10k lbs) 8,000–30,000+ lbs/pair ✅ High rigidity, seismic-ready
❌ 20–40% more expensive
Key Specs:
Length:
Beam Length = (Bay Width) + 1–2".
Example: 48" deep pallets × 2 → 96–98" beam length.
Depth (Height):
→ Standard: 3", 4", 5", 6".
→ Deeper = higher capacity (a 6" beam holds 15–25% more than a 4" beam at same length).
Step 2: Match Beams to Frames
Hole Compatibility:
Ensure beam connectors (Tee-ends, boltless pins) fit your frame’s hole spacing (e.g., 3" or 4" vertical slots).
Pallet Rack Support Beams
These horizontal components hold pallets and transfer loads to upright frames.
Beam Type Roll-Formed: Light/medium duty (C-shaped lips).
Structural: Heavy-duty (boxed/tubular; higher capacity.
Length Matches bay width (e.g., 96" for 48" deep pallets × 2). Always add 1–2" clearance per pallet.
Height (Depth) Standard: 3", 4", 5", 6".
Rack Decking is what the actual shelf is made out of. This is important to consider when planning what you’re actually going to put on the pallet rack. For instance, if you’re putting large items on your racks, then a will work well, as they allow a load of up to 2500 pounds of uniformly distributed weight. But if you have small or thin items that might fall through the holes in the wire mesh, then something more consistent like a perforated steel or solid steel deck might be a better solution.
Keep in mind that the weight of your load matters. While the frames and beams might support the weight of your materials, if the decking can’t support the weight, it likely to break through the shelf and crash into what’s below. Fire safety is also a consideration, so if you have flammable materials, or items that could spark and cause a fire, wood decking may not be the best option.
Safety is everyone’s top priority, so you’ll likely want to add some extra items to increase the safety of your rack system:
Anchors – Pallet rack that is not anchored to a concrete floor is extremely unsafe. You need four anchors installed per frame. Anchoring pallet rack is an essential part of proper pallet rack installation.
Column Guards – Damaged pallet rack is unsafe, and the most common damage to a frame happens when it is hit by a forklift. Installing column guards on each frame can reduce the likelihood of damage during low speed impacts. Any exposed side of a frame needs protection with a column guard solution such as a RAMguard or a column guard.
Drop Pins – Beam safety drop pins are an easy and inexpensive way to reduce the chance of beams being accidentally disengaged. This common error happens when a forklift operator lifts a pallet too high, causing the pallet to raise the beam above and disconnect it from the frame. This results in the entire beam level failing and pallets falling to the floor. Installing two drop pins per beam prevents this type of accident.
pallet racking usually need to be customized according to specific needs, mainly for the following reasons:
Space and storage requirements
pallet racking need to be designed according to the actual size of the warehouse and the type of goods, optimizing space utilization. For example, heavy-duty shelves can carry 3-5 tons of goods and require thicker design to meet load-bearing requirements; The high-level three-dimensional shelves need to adjust the number of layers according to the warehouse height to avoid space waste.
BS EN 15512 – This standard provides guidelines for the design and construction of adjustable pallet racking systems.
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