When planning a new warehouse storage system, one of the most important decisions is choosing the right pallet racking layout. A well-designed selective pallet racking system can significantly increase storage capacity, improve forklift efficiency, and reduce operational costs.

Many warehouse owners focus only on the price of pallet racking. However, the real value lies in designing a warehouse racking solution that maximizes available space while ensuring safety and operational efficiency.

In this article, we’ll walk through a real warehouse pallet racking design example and explain how professional racking manufacturers create a complete warehouse racking layout based on customer requirements.

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Warehouse Information and Storage Requirements

The customer provided the following warehouse specifications:

Warehouse Dimensions

• Warehouse Length: 48 meters
• Warehouse Width: 18 meters
• Clear Height: 11.5 meters

Pallet Specifications

• Pallet Size: 1200mm × 1200mm
• Pallet Load Capacity: 1000kg
• Loaded Pallet Height: 1500mm

Material Handling Equipment

• Counterbalance Forklift

Based on these parameters, we can begin designing an efficient selective pallet racking system.

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Step 1: Calculate the Beam Length

The first step in pallet racking design is determining the appropriate beam length.

In this project, each beam level is designed to store two pallets.

To allow safe forklift operation, industry standards recommend leaving clearance between pallets and rack uprights.

Recommended Clearance

• 100mm between pallets
• 100mm between pallet and upright frame on each side

Calculation:

1200mm + 1200mm + 100mm + 100mm + 100mm

= 2700mm

Therefore, the minimum beam length should be:

2700mm Beam Length

This size is one of the most commonly used beam lengths for selective pallet racking systems.

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Step 2: Determine Rack Depth

The next step is calculating the rack depth.

Since the pallet depth is 1200mm, the pallet should overhang the beams slightly on both the front and rear sides.

Industry standards typically recommend:

• 50mm–100mm pallet overhang on each side

Therefore, the recommended frame depth is:

1000mm Rack Depth

This configuration provides:

• Safe pallet placement
• Better load stability
• Reduced risk of pallet collapse
• Improved forklift handling

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Step 3: Determine Rack Height

The warehouse clear height is:

11.5 meters

To comply with fire protection systems, lighting requirements, and safety regulations, it is recommended to keep the highest load level below 11 meters.

Therefore:

Recommended Upright Height

10.5 meters (10500mm)

This height fully utilizes the available warehouse space while maintaining safe operating clearances.

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Step 4: Calculate Vertical Storage Levels

The loaded pallet height is:

1500mm

To allow safe forklift operation, a minimum clearance of 200mm should be maintained between the top of the load and the bottom of the beam above.

Calculation:

1500mm + 200mm

= 1700mm

Therefore:

Minimum Clear Height Per Level

1700mm

This spacing ensures smooth loading and unloading operations.

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Step 5: Determine the Number of Storage Levels

With a rack height of 10.5 meters, we can design:

• Ground storage level
• Five beam levels above

Total:

6 Pallet Storage Levels

This configuration is widely used in high-bay warehouses and distribution centers.

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Step 6: Calculate Forklift Aisle Width

The customer uses a counterbalance forklift.

For safe maneuvering, the aisle width should be at least:

Minimum Forklift Aisle Width

3000mm

This allows efficient pallet handling while maximizing storage density.

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Step 7: Create the Warehouse Racking Layout

Based on the warehouse dimensions:

48m × 18m

The recommended layout includes:

• Double-deep back-to-back rack rows
• Single rack rows along walls
• 3000mm forklift aisles

After optimizing the warehouse floor plan, the preliminary design includes:

Rack Configuration

• Approximately 98 rack bays
• 5 beam levels
• 6 pallet levels including floor storage

Each bay stores:

• 2 pallets per level

Total pallet positions:

98 × 6 × 2

= 1176 pallet locations

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Final Warehouse Pallet Racking Design Summary

Warehouse Size

• Length: 48m
• Width: 18m
• Height: 11.5m

Rack Specifications

• Beam Length: 2700mm
• Rack Depth: 1000mm
• Upright Height: 10500mm
• Beam Levels: 5
• Storage Levels: 6

Storage Capacity

• 98 Rack Bays
• 1176 Pallet Positions

Load Capacity

• 1000kg per pallet

Total Warehouse Storage Capacity

Over 1,176 tons of stored goods

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How to Select the Right Materials for a Pallet Racking System

One of the most common questions from warehouse managers is:

“What rack specifications should I choose for 1000kg pallets?”

The answer depends on load calculations, beam span, rack height, and safety factors.

For this project:

Load Per Beam Level

2 pallets × 1000kg

= 2000kg per level

Recommended rack components:

Upright Frames

• 90×70×2.0mm
• 100×70×2.0mm

Box Beams

• 100×50×1.5mm
• 120×50×1.5mm

Final specifications should always be verified through structural load calculations performed by an experienced pallet racking manufacturer.

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Why Professional Warehouse Racking Design Matters

Many businesses purchase warehouse racking based solely on price.

However, poor warehouse planning often results in:

• Wasted warehouse space
• Lower storage capacity
• Inefficient forklift operation
• Future expansion difficulties
• Increased safety risks

A professional warehouse racking design should include:

• Warehouse measurement analysis
• Pallet size evaluation
• Load capacity calculations
• Forklift turning radius assessment
• Structural engineering review
• Warehouse layout drawing
• 3D racking design and visualization

Only a professionally designed pallet racking system can maximize warehouse efficiency and long-term return on investment.

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Conclusion

For a warehouse measuring 48m × 18m with a clear height of 11.5m, a selective pallet racking system offers an ideal balance between storage density, accessibility, and cost efficiency.

Using:

• 2700mm beams
• 1000mm rack depth
• 10500mm upright frames
• 5 beam levels
• 6 pallet storage levels

The warehouse can accommodate approximately:

1,176 Pallet Positions

This design significantly improves storage utilization while maintaining safe and efficient forklift operations.

If you are planning a new warehouse or expanding your storage capacity, our engineering team can provide customized warehouse racking layouts, pallet rack calculations, 3D warehouse designs, and detailed quotations tailored to your requirements.

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