{"id":1280,"date":"2026-06-22T15:37:05","date_gmt":"2026-06-22T07:37:05","guid":{"rendered":"https:\/\/omniracking.com\/?p=1280"},"modified":"2026-08-14T16:03:10","modified_gmt":"2026-08-14T08:03:10","slug":"how-to-design-a-pallet-racking-system","status":"publish","type":"post","link":"https:\/\/omniracking.com\/en\/how-to-design-a-pallet-racking-system\/","title":{"rendered":"How to Design a Pallet Racking System That Perfectly Fits Your Warehouse?"},"content":{"rendered":"
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BLOG \u00b7 WAREHOUSE DESIGN<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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How to Design a Pallet Racking System That Perfectly Fits Your Warehouse?<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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By Admin \u00b7 June 22, 2026 \u00b7 Home \u203a News \u203a Pallet Racking Design<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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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.<\/p>

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.<\/p>

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.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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Warehouse pallet racking system<\/h2>\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t
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Warehouse Information and Storage Requirements<\/h2>\t\t\t\t<\/div>\n\t\t
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Warehouse Dimensions<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Length: 48 meters
Width: 18 meters
Clear Height: 11.5 meters<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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Pallet Specifications<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Pallet Size: 1200\u00d71200mm
Load Capacity: 1000kg
Loaded Height: 1500mm<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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Handling Equipment<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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Counterbalance Forklift<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n\n<\/div>\n

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01<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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Calculate the Beam Length<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n\n<\/div>\n
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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.<\/p>\n

Recommended Clearance:
\u00b7 100mm between pallets
\u00b7 100mm between pallet and upright frame on each side<\/p>\n

Calculation: 1200mm + 1200mm + 100mm + 100mm + 100mm = 2700mm<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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RECOMMENDED BEAM LENGTH<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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2700mm<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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02<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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RECOMMENDED RACK DEPTH<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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The next step is calculating the rack depth.<\/p>\n

Since the pallet depth is 1200mm, the pallet should overhang the beams slightly on both the front and rear sides.<\/p>\n

Industry standards typically recommend:<\/p>\n

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  • 50mm\u2013100mm pallet overhang on each side<\/li>\n<\/ul>\n

    Therefore, the recommended frame depth is:<\/p>\n

    1000mm Rack Depth<\/h3>\n

    This configuration provides:<\/p>\n

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    • Safe pallet placement<\/li>\n
    • Better load stability<\/li>\n
    • Reduced risk of pallet collapse<\/li>\n
    • Improved forklift handling<\/li>\n<\/ul>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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      RECOMMENDED RACK WIDTH<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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      1000mm<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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      03<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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      \tRECOMMENDED UPRIGHT HEIGHT<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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      The warehouse clear height is:<\/p>\n

      11.5 meters<\/h3>\n

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

      Therefore:<\/p>\n

      Recommended Upright Height<\/h3>\n

      10.5 meters (10500mm)<\/p>\n

      This height fully utilizes the available warehouse space while maintaining safe operating clearances.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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      RECOMMENDED UPRIGHT HEIGHT<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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      10500mm<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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      04<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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      \tMINIMUM CLEAR HEIGHT PER LEVEL<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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      The loaded pallet height is:<\/p>\n

      1500mm<\/p>\n

      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.<\/p>\n

      Calculation:<\/p>\n

      1500mm + 200mm<\/p>\n

      = 1700mm<\/p>\n

      Therefore:<\/p>\n

      Minimum Clear Height Per Level<\/h3>\n

      1700mm<\/p>\n

      This spacing ensures smooth loading and unloading operations.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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      RECOMMENDED HEIGHT PER LEVEL<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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      1700mm<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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      05<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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      TOTAL STORAGE LEVELS<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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      With a rack height of 10.5 meters, we can design:<\/p>\n

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      • Ground storage level<\/li>\n
      • Five beam levels above<\/li>\n<\/ul>\n

        Total:<\/p>\n

        6 Pallet Storage Levels<\/h3>\n

        This configuration is widely used in high-bay warehouses and distribution centers.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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        RECOMMENDED STORAGE LEVELS<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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        \t6 Levels<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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        06<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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        \tMINIMUM FORKLIFT AISLE WIDTH<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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        The customer uses a counterbalance forklift.<\/p>\n

        For safe maneuvering, the aisle width should be at least:<\/p>\n

        Minimum Forklift Aisle Width<\/h3>\n

        3000mm<\/p>\n

        This allows efficient pallet handling while maximizing storage density.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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        RECOMMENDED FORKLIFT AISLE WIDTH<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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        \t\t3000mm<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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        07<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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        \tTOTAL PALLET POSITIONS<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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        Based on the warehouse dimensions:<\/p>\n

        48m \u00d7 18m<\/p>\n

        The recommended layout includes:<\/p>\n

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        • Double-deep back-to-back rack rows<\/li>\n
        • Single rack rows along walls<\/li>\n
        • 3000mm forklift aisles<\/li>\n<\/ul>\n

          After optimizing the warehouse floor plan, the preliminary design includes:<\/p>\n

          Rack Configuration<\/h3>\n
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          • Approximately 98 rack bays<\/li>\n
          • 5 beam levels<\/li>\n
          • 6 pallet levels including floor storage<\/li>\n<\/ul>\n

            Each bay stores:<\/p>\n

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            • 2 pallets per level<\/li>\n<\/ul>\n

              Total pallet positions:<\/p>\n

              98 \u00d7 6 \u00d7 2<\/p>\n

              = 1176 pallet locations<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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              TOTAL PALLET POSITIONS<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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              \t\t1,176<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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              Final Warehouse Pallet Racking Design Summary<\/h2>\t\t\t\t<\/div>\n\t\t
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              48\u00d718m<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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              Warehouse Size (11.5m height)<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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              2700mm<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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              \tBeam Length \/ 1000mm Depth<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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              98 Bays<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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              5 Beam Levels \/ 6 Storage Levels<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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              1,176<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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              \tPallet Positions (1,176 Tons Capacity)<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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              Using 2700mm beams, 1000mm rack depth, and 10500mm upright frames across 98 rack bays, this warehouse achieves approximately 1,176 pallet positions with a total storage capacity exceeding 1,176 tons.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\n<\/div>\n

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              How to Select the Right Materials for a Pallet Racking System<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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              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.<\/p>\n

              For this project, load per beam level is 2 pallets \u00d7 1000kg = 2000kg per level.<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t

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              Upright Frames<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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              90\u00d770\u00d72.0mm \/ 100\u00d770\u00d72.0mm<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n
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              Box Beams<\/h2>\t\t\t\t<\/div>\n\t\t\t\t
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              100\u00d750\u00d71.5mm \/ 120\u00d750\u00d71.5mm<\/h2>\t\t\t\t<\/div>\n\t\t\n<\/div>\n\n<\/div>\n
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              Why Professional Warehouse Racking Design Matters<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t

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              Many businesses purchase warehouse racking based solely on price. However, poor planning often results in:<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\n<\/div>\n\t\t<\/div>","protected":false},"excerpt":{"rendered":"

              BLOG \u00b7 WAREHOUSE DESIGN How to Design a Pallet Racking […]<\/p>\n","protected":false},"author":1,"featured_media":1060,"comment_status":"open","ping_status":"open","sticky":false,"template":"elementor_header_footer","format":"standard","meta":{"footnotes":""},"categories":[37],"tags":[],"class_list":["post-1280","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog"],"_links":{"self":[{"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/posts\/1280","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/comments?post=1280"}],"version-history":[{"count":7,"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/posts\/1280\/revisions"}],"predecessor-version":[{"id":1994,"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/posts\/1280\/revisions\/1994"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/media\/1060"}],"wp:attachment":[{"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/media?parent=1280"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/categories?post=1280"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/omniracking.com\/en\/wp-json\/wp\/v2\/tags?post=1280"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}