Pallet Racking 

Selective pallet racking is a modular, semi-rigid racking system made up of vertical frames and horizontal beams that clip together. It can be set up in different ways to suit the layout of a warehouse, the pallet sizes being used, or the weights being stored. Load capacities typically range from 500kg up to 4000kg per level. Frames go from 2.4m up to 9m high in 600mm increments, and beams run from 2.6m up to 4.8m, stepping up in roughly 300–400mm increments.

This system works in just about any environment; warehouses, factories, distribution centres, bulky goods showrooms, and even smaller sites that want to add mezzanine-style storage. It’s also the base for many specialist systems like double deep racking, tyre racking, carpet racking, or conduit racking. In fact, selective racking in its various forms makes up around 90% of industry storage requirements.

Drive-in racking is set up as a series of lanes where pallets sit on rails, usually four to five high and three to eight deep. It works on a first in, last out basis, so if you’re storing a lot of the same product, like frozen Christmas turkeys or chickens, and you want them in one condensed space, this is the way to go. If you’ve got a wide variety of stock though, it’s not as suitable.

Each lane is 1350mm wide, with levels spaced at about 1200mm so the pallets slide in and out smoothly. A typical three-level system stands around 5–6m high. Each pallet is generally about 1 tonne, with levels carrying up to 8 tonnes total. It works best in rectangular warehouses where space is tight, you only need one forklift entry point per lane.

Note that in Australia, drive-through (both-end entry) is no longer allowed, because bracing at the back is required to keep the structure stable.

Pallet racking protectors are there to stop forklifts from damaging the racking. The most common type is a column or post protector, a U- or L-shaped piece of steel that sits in front of the upright and takes the hit instead of the frame.

Then you’ve got the end-frame barriers, which protect the racking when forklifts drive in or out of aisles. They sit across the end bays and take the brunt of any accidental impact before it reaches the bracing. You’ll often see them used in drive-through areas or high-traffic sections of a warehouse.

They’re sacrificial pieces, if they bend or dent, they’re simply replaced. It’s a fraction of the cost compared to replacing a damaged frame or risking a collapse, and they’re now required under the Australian Standards for warehouse safety.