What is the process for selecting the right warehouse racking system for your needs?

Selecting the right warehouse racking system involves matching the storage equipment to your building, stock, handling methods, access requirements and operating conditions. The process should begin with a detailed site and operational assessment, followed by system design, load verification, safety checks and a planned installation.

1. Assess the warehouse and available space

The first stage is to establish how much usable space is available and how it can be used safely. This includes checking the building dimensions, clear height, floor condition, column positions, doorways, loading bays, lighting, sprinklers, fire routes and other fixed services. A site survey should also identify obstructions, uneven surfaces and areas where vehicles or pedestrians need protected access.

The layout must provide more than the maximum possible storage capacity. Sufficient clearance is needed for forklift movements, loading and unloading, stock inspection, maintenance and emergency access. A design that fills every available area may reduce efficiency if it creates restricted aisles or makes frequently handled goods difficult to reach.

2. Define the stock and loading requirements

The system must be designed around the goods it will support. Important information includes:

• the dimensions and weight of each load;
• whether goods are stored on pallets, shelves, stillages, containers or other supports;
• the number of pallets or items required at each location;
• the stability, fragility and packaging of the stock;
• the frequency with which goods are placed into and removed from storage; and
• any special requirements, such as food, chemical, long or unusually shaped products.

Load weights should be based on actual or planned operating conditions rather than average estimates. The heaviest intended load, the position of that load and the way it is placed into the system can all affect the required design. Any future changes to stock should be considered before the specification is finalised.

3. Review handling equipment and access needs

Forklifts, reach trucks, stackers and other handling equipment have different turning circles, lift heights and operating requirements. The selected system must be compatible with the equipment used in the warehouse, including the required aisle width, beam height, lifting capacity and visibility for the operator.

Access requirements also depend on the way stock is managed. High-throughput operations may require direct access to many individual loads, while slower-moving stock may be suited to a denser arrangement. Stock rotation, batch control, order picking and inventory accuracy should be included in the assessment. A system that offers greater density is not necessarily the best option if it slows picking or makes stock control more difficult.

4. Compare suitable warehouse racking options

The appropriate system depends on the balance between capacity, selectivity, product type and handling methods. Common options include:

• Pallet racking: suitable for storing palletised goods with direct access to individual locations. Beam levels can be configured to suit different pallet sizes and load heights.
• Adjustable shelving: useful for smaller items, cartons and hand-loaded stock where frequent picking is required.
• Longspan storage: appropriate for larger or heavier hand-loaded goods that need wider levels than conventional shelving.
• Drive-in or high-density systems: useful where maximising storage density is more important than direct access to every load, provided the stock profile and handling process are suitable.
• Cantilever storage: designed for long, bulky or irregularly shaped items that cannot be stored efficiently on standard pallet beams.

These options can be used individually or combined in different warehouse zones. The selection should be based on the actual operation rather than on capacity alone.

5. Check structural and safety requirements

Every proposed system must be checked against its intended loads, configuration and environment. This includes the upright frames, beams, connections, baseplates, floor fixings and any accessories or protection. The design should account for the effects of forklift impact, uneven loading, changes in beam levels and any unusual operating conditions.

Warehouse racking should be specified and installed in accordance with applicable UK requirements and recognised industry guidance. Relevant considerations include the manufacturer’s design information, BS EN 15629 for specification and planning, BS EN 15635 for the use and maintenance of storage equipment, and guidance from the Health and Safety Executive. Where the building, floor or loading conditions are unusual, input from a suitably qualified structural or design professional may also be required.

Fire protection, sprinkler clearance, lighting, emergency routes and workplace traffic management must be considered alongside the storage layout. These requirements can affect the maximum height, position and arrangement of the system.

6. Produce and review the design

A professional design should show the proposed layout, aisle dimensions, storage levels, load capacities, protection measures and access arrangements. It should be reviewed against the information gathered during the survey and checked with the people who will operate the warehouse.

This review is an opportunity to identify practical issues before installation. For example, a proposed beam level may be difficult for the handling equipment to reach, a pedestrian route may conflict with vehicle movements, or a high-demand product may be positioned too far from the despatch area. Adjustments are generally easier and less costly at the design stage than after the system has been installed.

7. Confirm the specification and plan installation

Before work begins, the final specification should confirm the system type, dimensions, load limits, components, fixings, protection and any restrictions on use. The installation plan should cover delivery access, work areas, vehicle and pedestrian segregation, working at height, lifting operations and coordination with other contractors.

Installation should be carried out by competent operatives in line with the approved design and the manufacturer’s instructions. Once complete, the system should be inspected to confirm that it has been assembled correctly, fixed securely and is suitable for the intended loads. Any changes made during installation should be recorded and assessed rather than accepted informally.

8. Establish safe use and ongoing review

Choosing a system is not the end of the process. Staff should understand the load limits, correct loading methods, prohibited alterations and the action to take if damage is found. Load notices should be clear and positioned where they can be read by the people using the system.

Regular visual checks should be supported by a structured inspection and maintenance arrangement. Damage from vehicle impact, displaced components, missing safety pins, overloading and unauthorised modifications should be reported promptly. A competent person should carry out a formal inspection at suitable intervals and after significant events, such as impact, relocation or a major change in use.

At Able Racking, the selection process is supported by practical site experience across warehouse racking surveys, installations, repairs and safety inspections. By combining the operational assessment with load verification and a realistic installation plan, the final system can provide the required storage capacity without compromising access, compliance or safe day-to-day use.