Bayset
Bayset is a leading Australian supplier of waterproofing, tiling, flooring and concrete repair systems, servicing commercial and residential construction projects through a growing national network of 14 branches. With each location operating as both a trade retail outlet and distribution warehouse, Bayset requires robust storage infrastructure capable of supporting heavy palletised products, efficient stock movement and future expansion.
QLD Storage Systems has worked with Bayset across numerous locations over many years, developing a consistent approach to warehouse racking design that can be replicated site to site. The Sunshine Coast project was a brand-new facility and formed part of Bayset’s continued national expansion.
Customised Racking
Racking & Shelving Solutions
Racking Audits
For Compliance & Efficiency
Budget-Friendly
Second-Hand Pallet Racking
The Challenge
Because the Sunshine Coast site was a new location, the primary objective was to maximise pallet storage capacity while preserving sufficient floor space for a future retail showroom. The warehouse footprint needed to work hard, balancing high-density storage with customer access and safe material handling.
One early complication was building height. The structure was not as tall as initially expected, which reduced the available vertical storage. This meant the original pallet count targets could not be met using a standard racking layout. To achieve the required capacity, the design had to work precisely within the physical constraints of the building.
Compounding this was the nature of Bayset’s product range. Most pallets weigh around 1,500 kilograms, meaning the racking system had to operate at the upper end of standard load capacities. Each bay needed to safely support up to nine tonnes of palletised goods, pushing the project firmly into the heavy-duty racking category.
The Implications
Without a carefully engineered layout, Bayset risked losing valuable storage capacity or encroaching into their retail area, limiting future growth and customer experience. The reduced ceiling height also meant that a poorly planned system could have resulted in inefficient use of vertical space, forcing the business to store less stock on site or rely on overflow storage elsewhere.
Given the weight of the products involved, any miscalculation in racking design, aisle spacing, or forklift access would have introduced safety risks and long-term operational issues.
Our Solution
QLD Storage Systems designed a heavy-duty selective pallet racking system tailored to both the building and Bayset’s operational requirements. A key part of the solution was designing the racking around the ceiling apex, the highest point of the roof, allowing maximum use of available height where the structure permitted it.
By carefully working within forklift turning circles and lift capabilities, additional pallet positions were created without compromising safety. In some areas, this also required close collaboration with Bayset to adjust pallet heights slightly, allowing extra storage capacity within the available clearance.
All racking was supplied new, with beams rated to three tonnes per level and overall bay capacities of up to nine tonnes. Rack protection was installed on ends and vulnerable locations to minimise forklift damage and protect Bayset’s long-term investment.
In addition to pallet racking, longspan shelving and workbenches were supplied for retail and packing areas as part of the broader fit-out. The system was also designed with future expansion in mind, including a second-stage installation of A-frame racking for conduit and long product storage.
The Results
The completed installation delivered a high-capacity, heavy-duty storage system that maximised the warehouse footprint without compromising the retail component of the site. Stock accessibility, safety, and load compliance were all achieved within the constraints of the building.
Just as importantly, the Sunshine Coast warehouse aligns with Bayset’s broader national strategy. The racking layout, load ratings, and design logic match their other sites across Brisbane and interstate. This consistency simplifies operations, staff training, inspections, and long-term maintenance across the entire business.
By standardising on a single racking system, typically Dexion or Dexion-compatible, Bayset avoids the complexity that comes with mixed-brand warehouses, where repairs and replacements become more difficult over time. The result is a safer, more efficient, and easier-to-manage warehouse network.
QLD Storage Systems understands how we operate and continues to deliver warehouse solutions that maximise storage, improve safety and support our national growth.
Maximise Your Space With QLD Storage Systems
This project highlights the value of designing warehouse racking systems that not only suit a single site, but support a growing national operation. QLD Storage Systems continues to work with Bayset across new locations and staged upgrades, providing consistent, heavy-duty racking solutions that scale with the business.
If your operation requires high-capacity pallet racking or a warehouse layout designed to balance storage, safety, and retail space, QLD Storage Systems can help. We specialise in engineered warehouse racking solutions built for long-term growth and operational consistency.
Maximise your space with QLD Storage Systems contact the team today on 07 5537 5999 or complete our online form.
Have A Question?
Looking for the right racking solution for your warehouse? Whether you’re unsure which system suits your stock, need help with custom sizing, or just want expert advice, we’re here to help.
Frequently Asked Questions
How long will it take to install my new storage system?
The time it takes to install your new storage system will depend on the size and complexity of the system. Larger, more complex systems such as racking may take longer to install; however, your storage specialist can give you an estimated time frame for your specific system.
Should I opt for racking or shelving for my business?
It really depends on what you’re storing and how often you need to access it. If you have heavy or awkwardly-shaped items, racking might be a better option. If you need to access your stored items frequently, shelving might be a better choice.
Do I need a pallet racking audit?
A pallet racking audit is a good idea if you’re considering installing or upgrading your pallet racking system. The audit will assess your current system and make recommendations for improvements. It’s a good way to ensure that your pallet racking is safe and fit for purpose.
Limited on Space?
Running out of space in your warehouse or office and wondering what you could do to avoid a costly relocation? We can help you go up rather than out and take advantage of your vertical space. Ask our team about Raised Storage Areas and Mezzanine Floors today.
Thank you and your team for such an easy install today. Quality work & appreciate your guys taking the time to talk through options while installing. Highly recommend
Menno and the team were excellent in helping us set up a new warehouse. Very quick turn around great price and excellent with dealing with any issue.
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