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Industrial Pallet Rack Systems

Q: How much weight can industrial pallet rack hold?

Standard selective rack holds 2,000 to 10,000 lbs per beam pair. Structural rack handles heavier loads. Every system should be engineered for specific requirements.

Q: Does pallet rack need to be anchored to the floor?

Yes. Building codes and OSHA require floor anchoring, especially in seismic zones like Utah.

Q: What is the difference between roll-formed and structural pallet rack?

Roll-formed uses lighter gauge steel and is cost-effective. Structural uses heavier hot-rolled steel with bolted connections for heavier loads.

Q: Do I need a permit for pallet rack installation?

Most jurisdictions require permits and engineered drawings for installations over a certain height or capacity.

Q: How wide should pallet rack aisles be?

12-13 feet for sit-down forklifts, 8.5-10 feet for reach trucks, 5-6 feet for narrow aisle trucks.

Q: Can you design a complete rack layout?

Yes. We provide full layout design including rack placement, aisle widths, fire lanes, and seismic engineering.

Q: Is wire decking required?

Many fire codes require it. Wire decking allows sprinkler water through and prevents pallets from falling between beams.

Q: Do you sell used pallet rack?

We primarily supply new rack systems for consistent quality and warranty coverage. Contact us to discuss budget-friendly options.

Selective, drive-in, pushback, cantilever, and specialty pallet racking for warehouses, distribution centers, and manufacturing facilities. Engineered for your load and layout.

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What Is Industrial Pallet Racking?

Industrial pallet rack is a steel storage system designed to hold palletized goods in horizontal rows on multiple levels. It is the backbone of modern warehouse storage, allowing facilities to store inventory vertically and maximize the use of available floor space and building height.

Pallet rack systems are engineered for specific load capacities, pallet sizes, and forklift access requirements. Choosing the right rack type, beam size, upright configuration, and layout directly impacts storage density, picking efficiency, and warehouse safety.

Material Handling USA designs and installs complete pallet rack systems for warehouses, distribution centers, manufacturing plants, and cold storage facilities. We handle layout design, engineering, seismic calculations, permitting support, delivery, and professional installation.

Types of Pallet Rack Systems

Selective Pallet Rack

The most common warehouse racking system. Every pallet position is directly accessible from the aisle, providing 100% selectivity. Best for operations with a high SKU count and frequent picking. Available in roll-formed (clip-in) and structural (bolted) configurations.

Drive-In and Drive-Through Rack

High-density storage where forklifts drive directly into the rack structure. Ideal for storing large quantities of the same SKU. Drive-in uses LIFO (last in, first out) access. Drive-through allows access from both ends for FIFO rotation.

Pushback Pallet Rack

Pallets are loaded from the front and pushed back on nested carts or rollers. When a pallet is removed, the next one rolls forward automatically. Stores 2 to 6 pallets deep per lane. Maximizes density without sacrificing aisle access.

View Pushback Rack →

Pallet Flow Rack (Gravity Flow)

Inclined roller lanes use gravity to move pallets from the loading end to the picking end. Provides true FIFO rotation for perishable goods, dated inventory, and high-throughput distribution. Essential for food, beverage, and pharmaceutical warehouses.

Gravity Flow Rack Guide →

Cantilever Rack

Open-front racking with horizontal arms instead of beams. Designed for long, bulky, or irregularly shaped items like lumber, pipe, bar stock, furniture, and sheet goods. Available in single-sided (wall mount) and double-sided (freestanding) configurations.

Structural Pallet Rack

Built with hot-rolled structural steel channels and bolted connections instead of roll-formed components. Designed for the heaviest loads, harshest environments, and applications where rack-supported structures carry the building roof or mezzanine floor.

Pallet Rack Components

Understanding the main components helps you specify the right system:

Uprights (Frames)

Vertical columns with diagonal bracing that support the load. Available in various heights, depths, and gauges. Heavier gauge = higher capacity.

Beams

Horizontal load-bearing members that span between uprights. Step beams hold pallets directly. Box beams accept wire decking or solid decking.

Wire Decking

Welded wire panels that sit on beams to provide a solid support surface. Required by fire codes in many jurisdictions to allow sprinkler water to reach lower levels.

Column Protectors

Steel guards that bolt to the floor around upright columns to absorb forklift impact and prevent structural damage.

Row Spacers and Ties

Horizontal members that connect back-to-back rows for stability. Required by seismic codes in many areas including Utah.

Base Plates and Anchors

Steel plates welded to the bottom of each upright column, anchored to the floor with concrete bolts for stability and seismic compliance.

How to Choose the Right Pallet Rack

If You Need…	Consider	Why
Access to every pallet	Selective	100% selectivity, fastest picking
Maximum density (few SKUs)	Drive-in	Eliminates aisles, stores deep
Density + aisle access	Pushback	2-6 deep, load/unload from aisle
FIFO rotation	Pallet flow	Gravity moves pallets, first in first out
Long/bulky items	Cantilever	Open arms, no beam interference
Heaviest loads / harsh environments	Structural	Bolted steel, highest capacity

Frequently Asked Questions

How much weight can industrial pallet rack hold?

Capacity depends on the beam length, beam size, upright gauge, and number of levels. A standard selective rack beam pair (96″ wide) typically holds 2,000 to 10,000 lbs. Structural rack can handle heavier loads. Every system should be engineered for the specific load requirements.

Does pallet rack need to be anchored to the floor?

Yes. Building codes and OSHA require pallet rack to be anchored to the concrete floor with expansion or epoxy anchors. This is especially critical in seismic zones like Utah where rack systems must resist earthquake forces.

What is the difference between roll-formed and structural pallet rack?

Roll-formed rack uses lighter gauge steel shaped by rollers. It is cost-effective for most warehouse applications. Structural rack uses heavier hot-rolled steel with bolted connections. It is more durable, handles heavier loads, and resists forklift impact better.

Do I need a permit for pallet rack installation?

Most jurisdictions require a building permit and engineered drawings for pallet rack installations over a certain height or weight capacity. We provide engineering and permit-ready drawings as part of our installation service.

How wide should pallet rack aisles be?

Standard aisle width depends on the forklift type. Sit-down counterbalance forklifts need 12-13 feet. Reach trucks need 8.5-10 feet. Narrow aisle (VNA) trucks can operate in aisles as narrow as 5-6 feet. Narrower aisles mean more storage density but require specialized equipment.

Can you design a complete pallet rack layout for my warehouse?

Yes. We provide full warehouse layout design including rack placement, aisle widths, fire lanes, seismic engineering, and capacity calculations. Send us your floor plan dimensions and inventory requirements and we will create a custom layout.

Is wire decking required on pallet rack?

Many local fire codes require wire decking to allow sprinkler water to pass through to lower rack levels. Wire decking also prevents pallets from falling through the beams and provides a secondary support surface. We recommend wire decking on all beam levels.

Do you sell used pallet rack?

We primarily supply new pallet rack systems to ensure consistent quality, capacity ratings, and warranty coverage. Contact us to discuss your budget and we will find the most cost-effective new solution for your requirements.