Installing or extending a storage area with pallet racks is a structuring project for any company. This type of industrial racking, also known as pallet racking, optimises the surface area of the warehouse, improves the flow of goods and enhances operational safety. But before taking the plunge, you need to prepare your project methodically. Good planning avoids costly mistakes, ensures compliance with standards and guarantees a durable installation. Here are the ten essential steps for designing your future pallet racking system.
1. Clearly define your needs
Every shelving project starts with a simple question: why do you need these racks and when? It could be a first-time installation, an extension or an adaptation to increased activity. If you already have shelving, you need to check the existing make and model to ensure that the new structures are compatible with the old ones. If, on the other hand, your warehouse is desperately short of space and goods are piling up in an untidy fashion, you need to take urgent action. Determining your objectives – whether related to growth, seasonality or logistical reorganisation – will help you to define the right type of racking and plan the project without haste.
2. Study the space available
The second step is to carefully analyse the storage space. The floor must be flat and able to support the total weight of the shelving and loaded pallets, because each pallet rack must be solidly fixed to the floor to guarantee the stability of the whole. Any obstacles must also be identified: steps, emergency exits, technical ducts or suspended light fittings. The height of the ceiling, beams or sprinklers can limit the useful height. If the shelving is leaning against a wall, you need to make sure that this configuration presents no risk. In short, a complete analysis of the environment will enable you to design an installation that is safe, functional and compliant with safety requirements.
3. Identify the goods to be stored
The choice of racking depends directly on the type of goods you are going to store. Between liquid products, small parts, bulky parcels or large pallets, requirements differ greatly. You also need to take into account the type of pallet used: European pallet, industrial pallet, plastic pallet or special pallet. The dimensions, stability and weight of the load influence the choice of rack, the width of the levels and the depth of the ladders. This stage ensures that each product will find its place in the chosen racking system.
4. Calculate the load capacity
Under-dimensioning a pallet rack is a common mistake that can have serious consequences. It is therefore essential to accurately assess the average weight of full pallets, as well as the number of pallets per level. You also need to consider the future: could the weight of goods increase over time? By anticipating these changes, you can guarantee the durability of your installation and avoid having to replace your shelving prematurely. Manufacturers always provide the permissible loads per level and per ladder: these data must be scrupulously respected to ensure the safety of your operators.
5. Determine the dimensions of the shelving
The design of pallet racking is not simply a matter of choosing a height and length at random. It is based on an overall approach: the size of the pallets, the number of levels, the height of the building and forklift access constraints. The height of the ladders, the spacing between levels, the width of the aisles and the length of the stringers all need to be calculated accordingly. A well-dimensioned installation allows maximum use to be made of the available volume while maintaining smooth, safe movement for handling equipment.
6. Assess the resources available
A good project must also take into account existing material and human resources. What is the overall budget you can allocate to your future racking? Are your current handling vehicles – front-end trucks, pallet trucks or stackers – compatible with the new lifting heights? Are your teams trained to use them? These factors have a direct influence on the configuration of the racking and the pace of installation. A successful project is one that integrates harmoniously with the logistics resources already in place.
7. Think about traffic lanes
Aisle planning is often overlooked, but it is essential. Their width depends not only on the type of truck used, but also on the storage strategy: narrow aisles to maximise capacity, or wide aisles to facilitate fast manoeuvring? The right balance needs to be struck between accessibility and density. In large warehouses, it is advisable to use clear floor markings to demarcate circulation and storage areas. This makes it easier to move around, reduces the risk of accidents and contributes to an orderly working environment.
8. Management and maintenance
Installing the racking is not the end of the project, but the beginning of its operation. Right from the design stage, you need to think about maintenance: who will regularly inspect the racks? Should this task be outsourced or entrusted to trained in-house staff? And what should be done in the event of impact or deformation of a ladder? Putting a clear procedure in place from the outset will ensure the longevity of the equipment and avoid unexpected stoppages in activity.
9. Integrating safety accessories
An industrial pallet racking system must always be fitted with appropriate safety devices. Ladder guards, trays, fall arrest grids or rear stops guarantee the stability of loads and the safety of personnel. Load signs must be visible and indicate the authorised weight limits. These accessories are not optional: they are an integral part of an installation that complies with SUVA standards or local regulations, and ensure a safe working environment.
10. Draw a sketch of the project
To finalise your preparations, we strongly recommend that you make a sketch, even a simple one. Drawing the layout of the racks, the dimensions of the space, obstacles and aisles will help you visualise the project and communicate more effectively with suppliers. This drawing summarises all the previous considerations and enables you to obtain an accurate quotation. This is also the time to check that pallet racking is the most appropriate solution. If you are storing long or very heavy products,cantilever racking may be more appropriate. Conversely, for manual storage without machinery, lightweight shelving will be more practical.
Good preparation for better storage
The key to a successful pallet racking project is careful preparation. By clearly defining your needs, constraints and resources, you can avoid the unexpected and maximise the performance of your warehouse. Racks are more than just metal structures: they are the heart of your logistics. That’s why Ecocube is with you every step of the way – from the first sketch to installation and annual inspection – to make your pallet racking project a safe, efficient and sustainable solution.