When fitting out a warehouse or storage area, a crucial question often arises: “Do I need special flooring to install a pallet rack?”
The answer is yes and no: it all depends on the type of rack, the load it has to support and the configuration of the warehouse. In this article, we explain the technical requirements for a suitable floor, good installation practices and how Mecalux solutions guarantee the safety and durability of your racks.
Why is the floor important for a pallet rack?
A pallet rack can support several tonnes on several levels. The stability of the structure depends directly on the floor:
- If the floor is uneven or too fragile, the rack may tilt or tip over.
- A floor that does not absorb loads properly can crack or collapse under the weight of pallets.
- An unsuitable floor can limit the rack’s load-bearing capacity, even if the structure itself complies with standards.
In short, safe storage starts with the floor.
Characteristics of a suitable floor
To accommodate a pallet rack, the floor must meet certain requirements:
- Flatness
- The slabs must be flat so that each rack leg rests evenly.
- A sloping or uneven surface requires levelling beforehand.
- Mechanical resistance
- The slab must be able to support the maximum load of the rack and pallets.
- Experts recommend reinforced concrete at least 15-20 cm thick for heavy racks.
- Can be fixed
- The floor must allow pallet rack plates to be anchored.
- The anchors or bolts must be able to penetrate the concrete properly to guarantee stability.
- Absorption of horizontal forces
- A rack can be subjected to lateral thrusts (forklift truck, vibrations).
- The floor must be capable of transmitting these forces without cracking.
Typical floors for pallet racks
| Type of soil | Benefits | Limitations |
|---|---|---|
| Reinforced industrial concrete | Ideal for heavy racks, guaranteed flatness, fastener compatible | Higher cost, requires treatment and maintenance |
| Lightweight concrete slab / industrial cladding | For medium loads, quicker to install | Less resistant for very heavy loads, requires technical study |
| Wooden or tiled floor | Rarely used, suitable for light racks | Not recommended for heavy loads or multi-level racks |
| Uneven or old flooring | Can be used after levelling | Requires work to secure anchorage and stability |
The importance of anchoring
Even with a suitable floor, the rack must be fixed to the ground. Anchor plates are sized according to :
- The type of floor (concrete, reinforced slab, etc.)
- Load per level and total rack load
- The height and width of the rack
Mecalux always provides a detailed installation guide, indicating the exact number of anchors and their position. This ensures that the rack remains stable even in the event of an accidental impact or overload.
Best practice for installation
- Assess the strength of the floor with a professional before installation.
- Check flatness: correct any unevenness greater than 5 mm per metre.
- Choose the right anchors for the depth and density of the concrete.
- Follow the manufacturer’s assembly instructions (distance between uprights, level of shelves, fixing of plates).
- Plan regular inspections: check for cracks, subsidence and the condition of the anchors.
Conclusion
To install a pallet rack safely, the floor plays a fundamental role. Reinforced, flat and resistant concrete is ideal for supporting heavy loads and allowing solid fixing. An unsuitable floor can limit the rack’s capacity and pose a risk to operators and goods.
Mecalux solutions are designed to adapt to standard industrial floors and each installation is accompanied by precise recommendations on floor requirements and anchoring. By respecting these rules, you ensure the safety, stability and longevity of your warehouse.