Pallet rack inspection is a crucial part of an effective rack management system to maintain compliance, reduce damage, and ensure structural integrity …
Pallet Racking Dimensions are important in optimizing the warehouse space, ensuring safety, and getting proper accessibility. The key metrics for rack dimensions are depth, beam length, and height.
Standard rack depths typically range from 42 to 48 inches (107 to 122 cm or 1.07 to 1.22 meters), suitable for accommodating standard pallets of 40×48 inches (102×122 cm or 1.02×1.22 meters). Beam lengths generally range from 96 to 144 inches (244 to 366 cm or 2.44 to 3.66 meters), facilitating storing multiple pallets side by side. Heights range from 8 feet (244 cm or 2.44 meters) for smaller operations and extend up to 30 feet (914 cm or 9.14 meters) or more for high-capacity warehouses.
The dimensions vary with the types of pallet racking systems. Selective pallet racking dimensions will be different from drive-in and drive-through racking. The same will go for other racking types. When choosing the right dimension for the racking system, consider the storage requirements, ceiling height, warehouse length, and forklift specifications. Properly planned dimensions optimize the space and improve workflow.
The most common and standard upright rack dimension is 42” since this is suitable for 48” deep pallets. However, 36” and 48” are also available for 42” and 48” to 56” deep pallets, respectively. You will even find 24”, 30” and 44” upright dimensions. The standard heights for upright are 96 inches (8 feet or 2.44 meters), 120 inches (10 feet or 3.05 meters), 144 inches (12 feet or 3.66 meters), 168 inches (14 feet or 4.27 meters), 192 inches (16 feet or 4.88 meters), 216 inches (18 feet or 5.49 meters), and 240 inches (20 feet or 6.10 meters). The width is 3” on the outer face to make the calculation easier.
The average pallet rack beam dimension is 96″ x 4” for 5000 lbs. You will also find beams with 102″, 108″, 120″, 144″, 168”, and 192″ dimensions for up to 3 pallets to reduce the upright needs. The customization is also possible to satisfy your custom needs.
The standard height for warehouse racking ranges from 8′ to 24′. The US warehouse racking ranges from 20 to 30 feet. The height will vary depending on the rack type, storage needs, and warehouse ceiling height.
|
Rack type |
Depth |
Beam Length |
Upright height |
| Selective Racking | 42-48 inches (standard) | 96-144 inches (8-12 feet) | 8-30 feet |
| Drive-In/Drive-Through | 48-60 inches per pallet position | N/A | 12-30 feet |
| Push-Back Racking | 48 inches per pallet (2-6 deep) | 96-144 inches | Adjustable |
| Pallet Flow Racking | 48 inches per pallet (2-20 deep) | 96-144 inches | Adjustable |
| Cantilever Racking | 24-60 inches (arm length) | N/A | 8-20 feet |
| Double-Deep Racking | 96 inches (two pallets deep) | 96-144 inches | 10-30 feet |
| Mezzanine Racking | Customizable | 96-144 inches | 12-30 feet |
| Mobile Racking | 42-48 inches | Adjustable | Up to 30 feet |
You must maintain a 3-inch gap between the two pallets. For the last pallet, the gap is 3 inches between the last pallet and the upright frame. Besides, the gap between warehouse components like walls and the racking system has to be 200mm or 7.5 inches. The distance between two racks must be 600mm (24 inches) for a smooth forklift operation.
Measure the products’ width, depth, and height to identify the pallet size needs. Most of the pallets come in 48” deep by 40” wide. Measure your pallets’ depth, width, and height. At the same time, understand the average weight the pallets will handle. Record the maximum weight. Consider the industry to identify the inventory type and weight. Different industries require different pallet dimensions.
The frame depth determines the gap between load beams for better weight distribution. The pallet will overhang the beams by 3 inches. To achieve this overhanging, you should take a frame depth of 6 inches less than the pallet depth. For example, A 48-inch pallet will need a 42-inch frame depth for a 3-inch overhang on both sides. Some common frame depths are 42”, 48”, and 36”.
You must utilize the vertical space to reduce costs and improve storage capacity. Measure the ceiling height and leave 18–24 inches of clearance for safety and compliance. Consider the forklift reach to align your rack height to manage the inventory.
Beams determine the pallet placement and weight distribution. Pick 8-foot beams to accommodate two pallets (48 x 40) and 12-foot beams for three pallets. Keep 3 inches of clearance between pallets or pallets and uprights.
Your warehouse space plays a vital role in determining the rack dimension. Measure the ceiling height and aisle width to decide the vertical dimension of your rack.
Check your local codes and regulations while determining the height of your racks. More than 12 feet may trigger local fire safety inspections.
Consider future scaling while choosing a racking dimension. Your business may grow, requiring adjustable beams for easy expansion.
You must consult a racking expert for complex storage solutions or custom solutions. He or she will help you choose the exact dimensions to satisfy your needs.
What is the difference between pallet depth and pallet height?
Pallet depth refers to the length from back to front, whereas pallet height refers to the vertical dimension.
How do I determine the space between pallet rack levels?
Keep 4-6 inches of space between pallet rack levels for smooth forklift operation.
Can I add more levels to my pallet racks later?
Yes, you can add more levels to your pallet racks later if there is enough vertical space, no obstructions, no legal issues, and a strong structure to handle the levels.
Are there pallet racking dimensions suited for the food and beverage industry?
For the food and beverage industry, you can use the standard pallet racking dimensions (42”*28”*12’).
Are larger racking systems more cost-effective for big warehouses?
Yes, larger racking systems are more cost-effective for big warehouses.
How do I install pallet racks with non-standard dimensions?
Hire a professional to install pallet racks with non-standard dimensions. Avoid doing it yourself unless you have previous experience.
When it comes to racking, you can rely on Matco Distributor. We have been providing and installing pallet racks for the last 70 years, including selective, push-back, drive-in, pallet flow, Wire decking, cantilever racks and so on. Contact us to get professional help to maximize your warehouse efficiency.
70 years of experience in the industry taught us a few things.
OSHA Requirement For Pallet Racking
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