Pallet Rack Design & Installation Services
Complete pallet rack systems — selective, drive-in, push-back, cantilever, and carton flow. Free warehouse layout design with professional installation nationwide.
Talk with a specialist. Call (800) 326-4403 or Email Sales@MH-USA.com
Complete Pallet Rack Systems for Every Warehouse
From selective pallet rack to drive-in, push-back, cantilever, and carton flow — we design and install the right racking system for your inventory and operations.
Material Handling USA designs pallet rack systems for warehouses, distribution centers, manufacturing plants, and retail backrooms. We partner with Interlake Mecalux — one of the world’s largest pallet rack manufacturers — to deliver engineered racking solutions that maximize your vertical storage space, improve picking efficiency, and meet seismic and building code requirements.
Our pallet rack design process begins with your inventory data — pallet sizes, weights, SKU count, and throughput requirements. We analyze your floor plan, ceiling height, forklift equipment, and fire code constraints to recommend the optimal rack type and configuration. Whether you need basic selective rack for direct pallet access or high-density systems like drive-in, push-back, or pallet flow, we engineer layouts that handle your current volumesand scale with your growth.
Every system includes engineered drawings, seismic calculations where required, professional installation, and permit assistance. We also supply rack accessories including wire decking, pallet supports, column protectors, row spacers, and safety netting.
Interlake Mecalux selective pallet rack is roll-formed from high-strength steeland available with bolted or welded frame configurations. Beams are mounted to the frame and held in place with a patented piston lock connector that seats securely without toolsand resists accidental disengagement — yet allows easy rearrangement when adjusting beam levels. Layout options include single-deep systems for maximum SKU accessibility and double-deep systems that store two pallets deep to increase density while reducing aisle space. Your system configuration depends on the variety of SKUs stored, picking frequency, and forklift equipment capabilities.
Standard rack components include frames, beams, foot plates, horizontaland diagonal struts, shims, post protectors, end aisle protectors, shelf panels, row spacers, roll-in pallet supports, and double flanged pallet supports. We specify each component based on your load requirements, seismic zone, and building code constraints — ensuring your rack system carries the rated loads safely throughout its service life.
Pallet Rack Systems
Every rack type engineered for your specific inventory and throughput requirements.
Why Choose Our Pallet Rack Solutions?
Engineered designs, premium products, and professional installation — one source for your complete racking system.
Interlake Mecalux: World-Class Pallet Rack Manufacturing
Interlake Mecalux is one of the world’s largest manufacturers of pallet rack and warehouse storage systems. With manufacturing facilities across North America, Europe, and South America, they produce selective, drive-in, push-back, cantilever, and pallet flow racking from high-strength steel using automated roll-forming and welding equipment.
Interlake Mecalux selective pallet rack uses a patented piston lock beam connector that seats securely without toolsand resists accidental disengagement. Frames are available in bolted or welded configurations with capacities up to 48,000 pounds per frame. Beams range from 4 to 12 feet in standard lengths with step beam and box beam options for different load types.
Material Handling USA is an authorized Interlake Mecalux distributor, offering factory-direct pricing, engineering support, and professional installation. We handle the complete project — site survey, layout design, permitting, delivery, installation, and rack inspection — so you get a turnkey pallet rack system ready for use.
Pallet Rack Design Considerations
Key factors our engineers evaluate for every warehouse racking project.
- Pallet Size & Weight — standard 48×40, 48×48, and custom pallet dimensions with weight per pallet position
- Ceiling Height — available clear height determines the number of beam levelsand storage density
- Forklift Type — reach trucks, sit-down counterbalance, or turret trucks affect aisle width requirements
- SKU Count & Velocity — high-velocity picks need selective rack; bulk storage favors drive-in or push-back
- Seismic Zone — IBC seismic design category determines anchorage and bracing requirements
- Fire Code — in-rack sprinklers, flue space requirements, and commodity class ratings
- Floor Condition — slab flatness, load capacity, and joint layout affect rack placement
- Future Growth — we design rack layouts that accommodate projected inventory growth
Pallet Rack Design Considerations
Aisle Width Optimization: Aisle width is the single biggest factor in rack density. Standard sit-down counterbalance forklifts require 12-13 foot aisles. Reach trucks reduce aisles to 8-10 feet. Turret trucksand VNA (very narrow aisle) systems can operate in aisles as narrow as 5-6 feet. Choosing the right forklift-aisle combination for your operation can increase pallet positions by 30-50% in the same building footprint. We analyze your forklift fleet and throughput requirements to determine the optimal aisle width for your operation.
Seismic Design: If your warehouse is located in a seismic zone (most of the western United States, including Utah), pallet rack must be engineered to withstand earthquake forces. The International Building Code (IBC) requires rack systems in seismic design categories C through F to meet specific anchorage, bracing, and connection requirements. Interlake Mecalux racks are engineered and tested for seismic applications, and we provide the structural calculationsand stamped engineering documents required for building permits in seismic zones.
Fire Code Compliance: NFPA 13 and local fire codes impose specific requirements on pallet rack installations — including in-rack sprinkler placement, transverse and longitudinal flue space maintenance, and commodity classification-based protection levels. High-piled combustible storage triggers additional requirements in most jurisdictions. We coordinate with your fire protection engineer to ensure your rack layout meets all applicable fire code requirementsand provide the documentation needed for fire marshal approval.
Floor Slab Evaluation: Pallet rack systems impose concentrated loads through frame baseplates into the floor slab. We evaluate your slab thickness, reinforcement, joint layout, and soil conditions to verify the floor can support the proposed rack loading. Rack frames must be anchored to the floor slab — we specify anchor bolt types, embedment depths, and edge distances based on your slab construction and the seismic requirements of your location.
Pallet Rack FAQs
How much does pallet racking cost?
Selective pallet rack typically costs $50-150 per pallet position installed, depending on height, load capacity, wire gauge, and accessories like wire decking and column protectors. Drive-in, push-back, and cantilever systems cost more per position but provide higher storage density that often results in lower cost per pallet on a total-project basis. We provide free engineering and quotes — send us your floor plan and inventory data.
How long does installation take?
A typical warehouse rack installation takes 1-4 weeks depending on size and complexity. A 200-position system might install in 3-4 days; a 2,000-position warehouse takes 2-3 weeks. We can phase installations to keep sections of your warehouse operational during the project, and our crews can work nightsand weekends when needed.
Do I need a permit for pallet rack?
Many jurisdictions require building permitsand engineered drawings for pallet rack installations, especially for high-pile storage configurations. We provide the complete engineering package — structural calculations, seismic analysis, layout drawings, and anchor bolt specifications — and assist with permit applicationsand inspections.
How do I know what rack type to use?
The choice depends on your SKU count, pallet volume, throughput requirements, and forklift equipment. Selective rack provides direct access to every pallet and suits diverse inventories with frequent picks. Drive-in and push-back suit bulk storage of fewer SKUs where LIFO rotation is acceptable. Pallet flow suits high-volume FIFO applications like food and beverage. We analyze your inventory data and operations to recommend the optimal system.
Can existing rack be reconfigured?
Yes. We can add beam levels, extend rows, install wire decking, replace damaged components, and reconfigure existing Interlake Mecalux and other manufacturer rack systems to accommodate changing inventory needs. We also buy and sell used pallet rack for customers looking to expand on a budget or liquidate excess racking.
What maintenance does pallet rack require?
Annual inspections per ANSI MH16.1 and RMI standards are recommended — checking for beam deflection, frame damage, missing safety clips, overloading, and anchor bolt integrity. We offer professional rack inspection services with detailed reportsand can repair or replace damaged components to maintain safe operation and code compliance.
Why Choose Material Handling USA for Your Pallet Rack System?
Material Handling USA is an authorized Interlake Mecalux distributor with extensive experience designing and installing pallet rack systems for warehousesand distribution centers of all sizes. Our engineering team designs rack layouts that maximize your storage density, support your operational workflows, and meet all applicable building codesand seismic requirements.
From initial site survey through engineering, permitting, delivery, installation, and final inspection, we manage every phase of your pallet rack project. Our installation crews are factory-trained and follow strict quality and safety protocols. We stand behind our work with installation warrantiesand ongoing support including rack inspections, repairs, and reconfigurations as your business evolves. Call (800) 326-4403 for a free warehouse analysis.
Warehouse Types We Design For
Material Handling USA designs pallet rack systems for every type of warehouse and distribution operation. General warehousing operations storing diverse product lines on standard pallets are our most common project — selective rack with wire decking provides direct access to every pallet position for operations with many SKUsand frequent picks. Our engineering team optimizes beam levels, aisle widths, and rack heights based on your specific forklift equipment and building dimensions.
Cold storage and freezer warehouses present unique design challenges — fork trucks operating in sub-zero temperatures, condensation on steel surfaces, and the high cost per square foot of refrigerated space make optimal rack density essential. We design drive-in and push-back rack systems that maximize pallet positions per cubic foot of cooler/freezer space, and specify galvanized or cold-rated components that perform reliably in extreme temperature environments.
E-commerce fulfillment centers require a different approach — high SKU counts with varying item sizes demand a combination of pallet rack for bulk storage, carton flow rack for fast-pick positions, and wide-span shelving for each-pick items. We design multi-zone fulfillment centers where pallet rack feeds a forward-pick area with carton flow modules, creating an efficient inventory flow from receiving to packing and shipping.
Manufacturing facilities use pallet rack for raw material storage, work-in-process staging, and finished goods holding. We coordinate rack layouts with production flow, dock door locations, and forklift traffic patterns to minimize material handling time and distance. Cantilever racking for bar stock, sheet goods, and long materials integrates into the overall warehouse layout alongside selective and bulk storage systems.
Third-party logistics (3PL) warehouses, retail distribution centers, and food and beverage operations each present unique rack design challenges thatour engineering team has solved across hundreds of installations. Whether you’re storing ambient groceries, frozen foods, automotive parts, building materials, or consumer electronics, we design racking systems that match your commodity type, pallet configuration, throughput requirements, and regulatory environment.
Ready to Design Your Pallet Rack System?
Get a free warehouse layout and pallet rack quote. Our engineers will design the optimal racking system for your operations.