So you realize your warehouse needs more storage space and decide to buy a racking system. Great idea, but don’t go rushing into it. Many factors should be considered before you buy a new racking system. Asking yourself the right questions will save you time and money and optimize productivity. Here are the top 5 focus points that lead to the best decisions when planning your new racking project.
This guide covers the planning decisions that come before you buy. To compare rack types, see our guide to the 8 best pallet racking systems; once your system arrives, here’s how it’s installed and inspected, and how to vet the crew you hire.
1- Why Do You Need the Rack?
Before acquiring a pallet rack, ask yourself why you need one. Depending on the reasons, many different solutions will be available to you. For example, if your goal is to maximize storage, you should choose racks with greater storage density. If you need better product accessibility, you might consider racks that allow access to all your pallets; if your goal is to optimize warehouse space, fewer aisles and higher-density racks should be the solution. Every warehouse is different, with its own needs, problems, and solutions. Therefore, identifying your objective first will help you choose the product that is right for you.
2- What Types of Products Does Your Warehouse Store?
This aspect can easily fall under the radar, but it significantly influences the type of racks selected. From the different stocked goods to the services your warehouse offers—even the types of pallets you are using—it is essential to know what goes in and out of your pallet rack systems. Is your warehouse storing small, light products? Is it storing solid or liquid goods? Are they frozen and require refrigeration?
Table 1: Types of Products on the Shelves
| Solid | Liquid |
| Big | Small |
| Light | Heavy |
| Frozen | Perishables |
Table 2: Types of Pallets on the Shelves
| Irregular | Uniform |
| Single-Use | Reusable |
It is important to ask yourself these questions, as the rack’s structure can vary depending on your answers. Liquid goods are less stable and will react more if the rack is impacted, causing the liquid to be displaced. Also, certain racks, such as drive-ins or pallet flow racks, require reusable pallets. So, if your entire warehouse uses single-use pallets, make sure you are willing to switch. Almost every warehouse will store commodities, and some will be much more active in distribution, which implies higher forklift traffic and increased risk of damaging the racks. Some will also include machinery for wrapping or special product treatments that can affect the warehouse’s environment (heating and chemicals). Identifying all these conditions will make your planning easier and ensure you install the ideal rack for you.
3- Match the Rack Type to Your Operation
Your product mix, throughput, and density goals determine which rack type fits—selective, drive-in, push-back, pallet flow, cantilever, and more. Each suits different operations. Rather than repeat the full breakdown here, see our complete comparison with pros, cons, and costs: 8 Best Types of Pallet Racking Systems for Warehouses. Once you know the type, the factors below decide whether your building can actually support it.
4- Can Your Building and Floor Support the Racking?
Buildings have many features that affect a new racking project. For example, the floor must be able to support all the loads imposed by the storage racks. Factors such as slab thickness or heated flooring will affect the total load the racking systems can support. If you do not have access to the data, an examination by a specialized engineering consultant may be required. Also, consider the floor area available before installing a rack. This will ensure:
- The respect for building clearances
- The planning of large enough aisles for forklift movement
- The safe loading of materials
Next, make sure your racking configuration allows for the appropriate clearance from the ceiling to properly install the sprinkler systems. Finally, make sure the lifting equipment you are using is adapted to the dimensions of the new racks. High-ceiling warehouses can accommodate taller pallet racks, but there is a chance your forklifts cannot reach the top level of these racks, especially if you have been running with shorter ones all along. In that case, new forklifts would need to be acquired, which can lead to unplanned expenses.
5- What Seismic Zone Is Your Warehouse in?
The design of the pallet rack might be different if in a high seismic zone. The geographic region where the racking will operate should factor into your plan from the start, because seismic design requirements vary widely by location.
Below is a map of the seismic zones in the US. The pink regions, such as California and Hawaii, are well known for their seismic activity, but keep in mind that the border between Tennessee, Arkansas, Kentucky, Missouri, and Illinois is also a high-seismic zone. The same goes for South Carolina and Alaska. Therefore, pallet racks in these regions will be designed to withstand seismic activity.
 Figure 9: Seismic Zones in the US. Credit: Global Seismic Hazard Assessment Program |
 Figure 10: Seismic Baseplate |
Plan for Load Plaques and LARC Drawings
One planning step people forget: when you buy a new system, your manufacturer should supply the Load Application and Rack Configuration (LARC) drawings, and you’ll need a visible load-capacity plaque before the racks go into service. Build that into your project scope up front. For the full requirements and what happens if you later reconfigure, see why warehouse operators need LARCs.
As you can see, there are many things to consider when planning a new racking project. Luckily, Damotech’s certified rack engineers can guide you through the entire planning process. Talk to a rack safety expert to review your project.
Planning a New Racking Project: FAQs
What should I consider before buying a pallet racking system?
Before buying, work through five planning decisions: why you need the racking (density, accessibility, or space optimization), what products and pallets you store, which rack type fits your operation, whether your building and floor can support the system, and your warehouse’s seismic zone. Settling these before purchase prevents costly changes once the racking is on order.
Do warehouse floors need to be evaluated before installing racking?
Yes. The floor slab must be able to carry the loads the racking will impose, so factors like slab thickness and heated (in-floor) flooring affect how much a system can support. If you don’t have the slab data, a qualified engineering consultant may need to evaluate it before you finalize the rack design.
Should seismic zone be part of my racking plan?
Yes — identify your warehouse’s seismic zone early, because racking in higher-seismic regions is engineered differently and that affects the system you should specify. Build it into your plan before you buy rather than after. For how seismic forces act on racking, see our guide to seismic forces and warehouse pallet racks.
How much aisle and ceiling clearance should I plan for?
Plan aisles wide enough for your forklifts to maneuver safely, confirm your lift equipment can reach the top level of the new racks, and leave enough clearance from the ceiling to install sprinkler systems correctly. See our recommended clearances between pallet racks and building components for specifics.
What should my project scope include after the racking is chosen?
Plan for the paperwork and verification up front: your manufacturer should provide Load Application and Rack Configuration (LARC) drawings, and a visible load-capacity plaque should be posted before use. For the details, see why warehouse operators need LARCs.
