Efficient warehouse storage is critical to the success of any logistics, manufacturing, or distribution operation. A well-designed pallet racking system maximizes space, enhances productivity, improves inventory management, and ensures safety. Whether you’re setting up a new warehouse or optimizing an existing one, understanding the fundamentals of pallet racking design is essential.

In this post, we’ll cover the key factors to consider when designing a pallet racking system from the ground up.

Understand Your Inventory

The first step in designing any storage system is to know what you’ll be storing. Ask yourself:

• What are the dimensions (length, width, height) of your standard pallet?

• What is the maximum pallet weight?

• Are the loads uniform or do they vary in shape and size?

• How many pallets do you need to store?

Understanding your inventory ensures your racking system is both efficient and structurally sound.

Assess Your Warehouse Space

 

Before choosing a racking type or layout, analyze the physical space of your facility:

• Ceiling Height: This determines how many vertical storage levels you can have.

• Column Spacing: Warehouse support columns can limit aisle width and racking continuity.

• Dock Locations: These influence the flow of goods in and out of storage.

• Clearances and Regulations: Ensure compliance with fire codes, seismic considerations, and OSHA safety requirements.

Efficient use of cubic space (not just floor space) is key.

Choose the Right Racking Type

There are several types of pallet racking systems, each suited for specific use cases:

• Selective Racking: The most common system. Offers direct access to each pallet and is ideal for operations with a high SKU count and lower pallet quantities per SKU.

• Drive-In/Drive-Thru Racking: Maximizes space by allowing forklifts to enter the racking system. Suitable for high-density storage of homogeneous products.

• Push Back Racking: Pallets are stored on carts that roll on inclined rails. Great for LIFO inventory systems.

• Pallet Flow (Gravity Flow) Racking: Uses rollers and gravity to move pallets from the loading end to the picking end. Ideal for FIFO inventory.

• Cantilever Racking: Best for long or irregular-shaped items like pipes or lumber.

The choice depends on your inventory type, turnover rate, and picking methods.

Plan for Accessibility and Efficiency

A good racking system balances density with accessibility. Consider:

• Aisle Width: Narrow aisles increase storage density but require specialized lift equipment.

• Pick Path Optimization: Arrange racking to reduce travel time for pickers and forklifts.

• Zone Storage: Group similar or frequently accessed items together.

Also, design with future expansion in mind—your storage needs may grow or change.

Factor in Safety and Maintenance

Safety is non-negotiable in warehouse operations. A racking design should include:

• Rack Load Labels: Clearly display weight limits on each rack.

• Rack Protection: Use corner guards, end-of-aisle protectors, and column guards.

• Inspection and Maintenance Plans: Regular checks for damage and wear can prevent accidents and extend the life of your system.

Make sure all designs comply with relevant standards like RMI/ANSI MH16.1 in the U.S.

Work with Professionals

Though it’s possible to sketch a basic layout yourself, working with an experienced rack designer or material handling consultant is highly recommended. They can help with:

• Load calculations

• Custom designs for unique inventory

• Permitting and code compliance

• Integrating automation (AS/RS systems, conveyors, etc.)

Professional input can save time, prevent costly mistakes, and ensure long-term scalability.

Designing a pallet racking system requires careful planning and an understanding of your inventory, space, and operational goals. The right system improves warehouse flow, reduces handling time, and boosts overall productivity. Whether you’re optimizing for density, speed, or SKU variability, the right racking solution is a foundational piece of efficient warehouse management.