Understanding the Different Types of Pallet Racking Systems

When to Upgrade Your Pallet Racking System

Knowing when to upgrade your pallet racking system is a critical decision. If your existing system is over 10 years old, shows signs of damage (such as bent beams, cracks, or corrosion), or no longer meets your operational needs, it may be time to consider an upgrade. Here are the key factors to evaluate:

• Assessing Warehouse Needs and Growth: Your racking system should scale with your business. If you’ve outgrown your current capacity or are planning facility expansion, your system may need to be reconfigured or replaced.
• Current System Limitations: Older systems may lack the flexibility for modern storage methods like double-deep or push-back racking. If your system can’t accommodate your current SKU mix or pallet sizes, an upgrade is warranted.
• Safety and Compliance Concerns: Damaged or non-compliant racking poses serious safety and liability risks. OSHA and local fire codes require racking systems to meet structural standards—regular inspections will reveal if your system is falling short.
• Technological Advancements: Modern racking systems support WMS integration, real-time inventory monitoring, and automation compatibility. If your current system is a barrier to adopting new warehouse technology, upgrading will pay dividends.
• Workflow Efficiency and Accessibility: Poor aisle configuration, limited selectivity, or inefficient pick paths all hurt throughput. An upgraded system designed around your workflows can meaningfully reduce labor costs.
• Expansion and Space Utilization: Vertical storage expansion or reconfiguration to higher-density systems can dramatically increase capacity without requiring a larger footprint.
• Cost-effectiveness and ROI: While the upfront cost of new racking is real, the long-term savings from reduced damage, lower labor costs, and better inventory control typically produce strong ROI within 2–5 years.
• Customization and Scalability: Modern racking systems can be customized for specific load requirements and scaled modularly as your operation grows—something older systems often can’t accommodate.
• Timing the Installation: Plan upgrades during slower operational periods. Work with your installer to phase the project in sections so warehouse operations can continue during the transition.

Why Your Warehouse Needs a Pallet Racking System

Beyond the specific system type, there are compelling operational reasons to invest in proper pallet racking rather than floor stacking or informal storage:

• Maximized vertical space – Floor stacking is limited by safe stack height and product stability. Racking uses full ceiling height, dramatically increasing storage capacity per square foot.
• Improved safety – Properly engineered racking prevents unstable stacks from collapsing on workers. OSHA requires racking systems to be designed to support their rated loads.
• Better inventory organization – Racking enables location-based inventory management, making every pallet traceable and accessible without moving other product.
• Higher productivity – Organized, accessible storage reduces pick travel time, eliminates double-handling, and allows forklifts to operate efficiently throughout the facility.
• Compliance with fire and building codes – Many jurisdictions require engineered storage systems for warehouses above certain square footage or ceiling height thresholds.

Industrial Shelving vs. Pallet Racking: Choosing the Right Solution

Pallet racking and industrial shelving serve different storage needs. Understanding when to use each is key to building an efficient warehouse storage system:

• Use pallet racking when: You store palletized loads, need high vertical storage, operate forklifts, or require dense storage of bulk quantities
• Use industrial shelving when: You store individual items, cartons, or totes that are hand-picked; need flexibility to adjust shelf heights frequently; or are managing a parts room, tool crib, or small items area
• Hybrid approach: Many warehouses use pallet racking for bulk storage and industrial shelving in pick modules, receiving areas, or value-added services areas where individual item handling is required

ROI of Upgrading to Structural Pallet Racking

When evaluating the switch from roll-formed to structural pallet racking, the ROI calculation should include both direct and indirect benefits:

• Extended lifespan – Structural racking typically lasts 20–30 years vs. 10–15 for roll-formed, reducing replacement costs over time
• Higher load capacities – Structural uprights handle heavier loads, enabling higher storage density per bay
• Reduced repair costs – Structural racking withstands forklift impacts better, resulting in fewer component replacements
• Lower insurance premiums – Fewer safety incidents from more durable racking can reduce workers’ compensation and liability costs
• Compliance advantages – Structural systems are easier to pass seismic inspections and high-pile storage audits in regulated markets like California

Factors to Consider When Choosing a Racking System

Selecting the right pallet racking system involves evaluating several key factors specific to your facility and operations:

• Load weight and dimensions – Consider the weight, size, and shape of your pallets or inventory units to ensure the system’s load capacity matches your needs.
• Storage density vs. accessibility – High-density systems like drive-in racking maximize space but limit access; selective racking offers full access to every pallet.
• Throughput requirements – High-velocity operations need systems that support fast retrieval; lower-throughput warehouses may prioritize density over speed.
• Inventory rotation (FIFO vs. LIFO) – Flow racking supports FIFO, which is critical for perishables; drive-in systems use LIFO.
• Seismic requirements – In California and other seismic zones, racking must be designed and permitted to meet local seismic codes enforced under the California Building Standards Commission code adoption process.
• Aisle width and forklift type – Your forklift fleet determines the aisle widths you need, which affects how much racking you can fit in your footprint.

Installation, Maintenance, and Safety

Proper installation is critical for the safety and longevity of any pallet racking system. Key considerations include:

• All racking must be installed per manufacturer specifications and local building codes
• Regular inspections should be conducted to identify damaged uprights, bent beams, or missing safety pins
• Column guards and row spacers should be installed to protect racking from forklift impact
• Load capacity labels must be posted on all rack systems per OSHA and RMI standards
• Staff should be trained on safe loading practices and weight limits

If you’ve been searching for a new pallet racking system to install in your warehouse, you’ll quickly discover that there are many types of unique racking systems available on the market. Since nearly every system has its advantages, it can sometimes be difficult to determine which option is right for your facility.

Before you buy a new pallet racking system, keep in mind that each system has specific applications that it’s ideally suited for. Knowing what these applications are can be helpful when you’re trying to narrow your options. This article offers a comprehensive overview of the different types of racking systems you can buy for your warehouse.

Selective Racking System

Selective pallet racking is a kind of static racking that’s used in warehouses more than any other solution in this guide. The main reason that it’s widely adopted is because of its affordable cost and expensive selection of beam sizes and upright heights. Your personnel will have full access to every load that’s stored on selective racking.

The benefits of selective pallet racking include:

• Easy to assemble and disassemble
• Ample configuration options to accommodate your industrial equipment
• More affordable pricing in comparison to complex pallet racking systems

The drawbacks of selective pallet racking include:

• System has many aisles, which makes for an inefficient use of floor space
• Less storage density in comparison to more modern racking types

Some of the applications this type of pallet racking can be used with include:

• When personnel need to always have access to every pallet
• Your warehouse has few pallets for each SKU
• Picking often occurs at lower levels
• Industries like pharmaceuticals, general manufacturing, and retail

Double-deep Pallet Racking

Double-deep racking systems have two rows of racks, which are installed in adjacent positions. In this scenario, you can take advantage of more storage density in comparison to selective pallet racking systems.

The benefits of double-deep pallet racking include:

• Many configurations
• High storage density
• Easy installation and assembly
• Low price point

The drawbacks of double-deep pallet racking include:

• Selectivity reductions by 50%
• More expensive equipment is necessary
• Double-deep reach truck must be paired with longer beams

Some of the applications this type of pallet racking can be used with include:

• Food and beverage
• General manufacturing and warehousing
• High storage density requirements
• First-in, first-out (FIFO) management solution

Drive-in Racking

Drive-in racking systems make it easy for companies to store a large amount of cargo in a relatively small area for better storage density. If you don’t have much warehouse space, this is the ideal racking solution. Operators drive directly into the system to perform loading and unloading processes.

The benefits of drive-in racking include:

• Increase storage space by getting rid of aisles
• Less warehouse space

The drawbacks of drive-in racking include:

• Uses the last-in, first-out (LIFO) method
• Forklifts are necessary, which leads to more risk
• Low selectivity
• All pallet sizes need to be the same

Some of the applications this type of pallet racking can be used with include:

• General warehousing with low product rotation
• Warehouse that requires high-density storage
• Non-perishable product storage

Drive-thru Racking

Drive-thru racking systems require the use of a forklift but allow for different sides to be used for the loading and unloading processes. An access aisle is necessary for loading, while the opposite end of the rack is used for unloading.

The benefits of drive-thru racking include:

• Lower retrieval and storage time
• Accommodates a more uniform load
• Energy-efficient storage solution
• Improves productivity and efficiency

The drawbacks of drive-thru racking include:

• Not great for high inventory turnover
• Less pick selectivity
• Possibility of forklift impact

Some of the applications this type of pallet racking can be used with include:

• Beverage industry
• Cooler systems
• General warehousing
• Chemical storage

Push-back Pallet Racking

Push-back pallet racking is ideal for warehouses that manage many different SKUs and need to maintain high storage density. These racks consist of pallets that are kept on inclined rails. When a pallet is loaded, it will push any stored pallets to the back. The loaded pallet at the back can then be removed.

The benefits of push-back pallet racking include:

• Many customization options available
• Lower labor costs
• No forklifts are necessary
• More pallet access
• High density storage

The drawbacks of push-back pallet racking include:

• Only allows five to six pallets deep
• Lower amount of vertical space
• More maintenance and higher costs
• Product damage is possible

Some of the applications this type of pallet racking can be used with include:

• Retail
• General warehousing
• FIFO or LIFO operations

Pallet Flow Racking

Pallet flow racking uses many of the same components as selective racking. However, these systems also come with roller tracks. At one side of the rack, loading takes place, while the opposite end is used for picking. When a pallet is loaded on the back, it will roll to the front of the queue with gravity rollers.

The Benefits of pallet flow racking include:

• Accommodates FIFO method, which keeps inventory from becoming stuck
• Efficient use of space
• Quick inventory turnover

The drawbacks of pallet flow racking include:

• Broken pieces can cause jamming
• Moderate maintenance requirements
• High cost

Some of the applications this type of pallet racking can be used with include:

• Grocery stores
• Freezer warehouses
• Food distribution centers

Cantilever Racking

Cantilever racking uses upright posts that are attached to arms for the storage of lengthier items, which include everything from lumber to pipes. They use vertical supports to assist with the storage of long loads.

The benefits of cantilever racking include:

• Perfect for unwieldy and long items in your warehouse
• Easy installation
• No vertical obstruction
• Numerous capacities

The drawbacks of cantilever racking include:

• Pallets can’t be stored
• Needs wide aisles
• Might require reinforced flooring

Some of the applications this type of pallet racking can be used with include:

• Construction suppliers
• Plumbing suppliers
• Metal and wood retail shops

Common Questions About Pallet Racking

Before you select any of these pallet racking systems, there are some commonly asked questions to consider.

What Is Pallet Racking?

Pallet racking systems are designed to store pallets of different items in rows that are situated along multiple levels. These systems provide more storage density by using a certain amount of vertical space.

What Are the Most Common Types of Racking?

The most common pallet racking system is selective racking. This system is more affordable and can be used with many different materials.

How Many Types of Pallet Stacking Are There?

The two forms of pallet stacking include block stacking and floor stacking. Block stacking involves placing pallets on top of each other. In comparison, floor stacking involves placing any number of pallets on the floor and stopping at one-pallet high. Floor stacking is the most basic solution.

How Many Types of Racking Systems Are There?

There are seven primary pallet racking systems, which include:

• Selective racking
• Double-deep racking
• Drive-in racking
• Drive-thru racking
• Pallet flow racking
• Push-back racking
• Cantilever racking

What Are the Various Parts of a Rack?

The many parts that make up a racking system include:

• Upright beams or posts
• Cross beams
• Footplate
• Crossbars
• Metal frames
• Shelf panels
• Diagonal struts
• Fastening components, which include clips, row spacers, and fasteners

What Are Storage Racks Used For?

Storage racks are mainly used to store materials and items in warehouses or holding bays. Pallets are placed on horizontal rows that go up multiple vertical levels. You can store everything from grocery items to forklift parts on a pallet racking system.

How Is Racking Measured?

If you want to measure pallet racks, three separate components should be measured, which include the wire decking, cross beams, and uprights. When measuring the beams, focus on the beam length and beam face. The four measurements that you should take with the uprights include the following:

• Frame height
• Frame depth
• Post depth
• Frame width

You can measure the depth of wire decking by identifying the post depth. The size of wire decking often depends on the specific decking material that you’re using.

What Are the Top Warehouse Rack Manufacturers?

The top warehouse rack manufacturers at your disposal include:

• QMH
• Steel King
• Interlake Mecalux
• Frazier Industrial
• Ridg-U-Rak

How Do You Identify Pallet Racking?

It’s possible to identify different racking systems by manufacturer name, product part number, or logo. Look at this pallet rack identifier if there isn’t a label on the system.

Choosing a Certified Manufacturer and Installer

Regardless of which racking configuration you choose, the system should be designed to the Rack Manufacturers Institute’s ANSI MH16.1 standard, which governs the design, testing, and utilization of industrial steel storage racks in the United States. Reputable manufacturers publish engineering data and load tables that reference this standard directly, and a qualified installer or PE-stamped layout drawing should cite the specific column, beam, and anchor capacities used in your design. QMH’s project consultants work directly with manufacturers and structural engineers to verify that a proposed layout meets both ANSI MH16.1 and the seismic or fire code requirements specific to your jurisdiction before installation begins.

It is also worth confirming how a prospective supplier handles ongoing compliance. Ask whether they provide load capacity signage, whether their crews are trained on OSHA’s powered industrial truck standard for safe forklift operation around racking, and whether they offer periodic post-installation inspections. These details are a strong indicator of a vendor who builds systems for long-term safety rather than the lowest up-front price.

Conclusion

From selective racking to drive-thru racking, there are a wide range of pallet racking systems available to you. Weigh the pros and cons of each to determine which system is right for your warehouse. Identify your warehouse needs before making a choice. Do you use the FIFO storage method? If so, push-back racking systems should suit your needs. When weighing your options, keep in mind that efficient storage solutions can boost warehouse productivity, keep your personnel safe, and reduce inventory loss.