How to Design the Setup of Pallet Racking in Your Warehouse

Designing pallet racking isn’t just about fitting as much storage as possible into a space. A well-planned layout makes your warehouse safer, more efficient, and fully compliant with Australian Standards. Here are the key things to consider when planning your racking setup.

Plan Your Runs

The direction of your pallet racking runs has a huge impact on workflow:

• Straight runs: Maximise storage and are ideal in larger spaces.

• Shorter runs with cross-aisles: Improve access and reduce travel time for forklifts.

• Avoid dead ends: Forklifts need space to turn without reversing long distances.

Allow for Forklift Traffic

Clearance is critical. When planning aisles, always check the specifications of your forklifts:

• Standard counterbalance forklifts usually require aisles of 3.5–4.0 m wide.

• Reach trucks can work in narrower aisles, around 2.5–3.0 m.

• Allow extra clearance at intersections and around doors to avoid congestion.

Remember, cramped aisles increase the chance of impacts and racking damage.

Consider Heights and Load Capacities

• Beam levels must match your pallet sizes and forklift lift heights.

• Top beam clearance should allow safe stacking without pallets fouling the roof, sprinklers, or lights.

• Always use the manufacturer’s certified load ratings for beams, bays, and pallets — never guess.

• Taller racks require greater attention to anchoring and frame bracing.

Think About Long Runs vs. Short Runs

• Long continuous runs maximise density but can limit access to individual bays.

• Shorter runs with gaps or cross-aisles allow flexibility, quicker picking, and easier stock rotation.

• Mix and match: some warehouses benefit from long bulk storage runs and shorter runs for fast-moving stock.

Don’t Forget Compliance

Every design must comply with AS 4084-2023 Steel Storage Racking, including:

• Correct beam deflection limits.

• Proper anchoring (two anchors per base plate).

• Load signage displayed and filled in accurately.

• Safe clearances for fire systems, building structures, and emergency exits.

Final Word

A well-designed pallet racking layout is a

bout more than just storage — it’s about safety, efficiency, and compliance. Plan your runs carefully, give forklifts enough space, set beam heights to suit your operations, and always stick to certified load ratings.

At Pallet Racking Inspections, we don’t just check racks — we can help review your setup and make sure it’s safe, compliant, and works for your warehouse.