Pallet racks: types, characteristics and how to choose for your warehouse

Pallet racks define the pallet storage scheme, the speed of access to goods, and the width of work aisles. The choice of system is tied to the weight of the pallets, the height of the room, the type of equipment, the number of SKUs, and the daily turnover.

Main types of pallet racks

Pallet racks are selected based on storage density, access to pallets, and product movement logic:

1. Front systems . Each pallet has direct access from the work aisle. The format is suitable for warehouses with a large number of SKUs, regular picking and frequent shipments.

2. Double Deep . Pallets are placed in two rows deep. The system increases the number of pallet spaces and works with a reach truck equipped with telescopic forks.

3. Drive-in . The forklift drives into the rack channel. Drive-in is optimal for large batches of the same type of product, refrigerated warehouses, and seasonal storage.

4. Gravity systems . Pallets move in roller channels from the loading area to the selection area. The scheme supports FIFO and stable batch turnover.

5. Mobile systems . Rack units are moved by rails. This scheme provides high storage density by reducing the number of permanent aisles.

After selecting the system type, calculate pallet spaces separately for fast-moving, batch and reserve goods. For frontal racks, determine the working aisle width for a specific model of equipment; for Drive-in, fix the LIFO or FIFO scheme; for gravity systems, immediately separate the loading and selection zones. This calculation shows the number of spaces on each tier, the required beam height, the permissible pallet weight and the actual throughput of the storage area.

Characteristics that influence the choice

To choose the right pallet racks , clearly define the technical parameters of the warehouse, cargo, and equipment for optimal frame design, tier height, number of pallet spaces, and aisle layout.

Parameter	What to record	What determines
Pallet weight	The maximum weight of a pallet with goods, packaging and stock for peak shipments	Cross-section of posts, type of beams, permissible load per tier
Warehouse height	Useful height to trusses, lights, ventilation, sprinklers and gates	Number of tiers, traverse height, working reserve for equipment
Type of equipment	Forklift model, lifting height, turning radius, fork type	Aisle width, rack depth, access to upper tiers
SKU count	Number of positions, turnover, frequency of selection, need for direct access	System type, number of addresses, product placement scheme
Product type	Dimensions, type of container, cargo stability, batch size, temperature regime	Storage format, protections, limiters, tier requirements

How to choose a pallet system for your warehouse?

Start with the cargo parameters. For a warehouse with active product selection, access to each pallet is a priority, and for batch storage, the number of pallet spaces in the available space is a priority.

1. Record the weight of the heaviest pallet with the goods and packaging.

2. Measure usable height to trusses, lighting, ventilation, and sprinklers.

3. Specify the type of warehouse equipment and the minimum working aisle width.

4. Separate goods by turnover, batches, dimensions, and access needs.

5. Compare front-end, Double Deep, Drive-in, gravity and mobile systems.

6. Prepare a diagram of the receiving, storage, picking, and shipping areas.

In the projects of the Ukrainian integrator of modern warehouse solutions Top Logistics Solutions Pallet racks are selected based on the equipment parameters, aisle width, lifting height, and cargo movement route. This calculation determines the number of pallet spaces, a safe equipment movement pattern, and a margin for warehouse scaling.