Pallet Racking: Structure, 6 Common Types and Safety Standards

 

The 6 most common types of pallet racking in Australia

The six most common pallet racking systems used across Australia are Selective,  Drive-In, Double-Deep, Pallet Flow, Push-Back and Radio Shuttle racking.

1. Selective Pallet Racking

Selective pallet racking is the most widely deployed system in Australian warehouses, and for good reason: it provides immediate, 100% direct access to every single pallet position without moving any other stock.

Each pallet sits in its own individual lane, fully reachable by a standard counterbalance or reach truck. This means your team can pick, replenish, or conduct cycle counts on any SKU at any time without repositioning other pallets.

• Access: 100% direct
• Density: Low
• Best for: High-SKU environments, frequent stock rotation, 3PL facilities, and operations where picking speed and inventory accuracy are critical.

2. Drive-In and Drive-Through Racking

Drive-in racking are high-density storage systems where the forklift physically drives into the bay structure to place or retrieve pallets — eliminating the conventional aisle between every row.

• Drive-In: A single entry and exit point per lane. Operates on a Last-In, First-Out (LIFO) basis. The forklift enters from one side only, placing the newest pallet at the front.
• Drive-Through: Entry from one end, exit from the other. Supports a First-In, First-Out (FIFO) rotation, making it suitable for date-sensitive goods.

Both configurations can achieve storage density increases of 60–85% compared to selective racking in equivalent floor areas.

• Access: Restricted (LIFO or FIFO sequence only)
• Density: Very high (60–85% more than selective)
• Best for: Bulk-storage operations with low SKU counts ambient grocery, beverages, building materials, and Australian cold stores

3. Double Deep Racking

Double deep racking stores pallets two rows deep on each side of an aisle, effectively doubling storage density per aisle compared to standard selective racking while maintaining a relatively straightforward structural footprint.

The front pallet must be retrieved before the rear pallet is accessible, so this system sacrifices direct access to every position in exchange for a meaningful density gain. A double-deep reach truck (equipped with a telescopic fork attachment) is required to place and retrieve the rear pallet without the forklift entering the rack structure.

• Access: Partial (front pallet direct; rear pallet requires front removal)
• Density: Moderate–high (~2× selective per aisle)
• Best for: Operations with moderate SKU counts and multiple pallets per SKU

4. Pallet Flow (Gravity Flow) Racking

Pallet flow racking uses slightly declined roller or wheel tracks typically pitched at around 4° to allow loaded pallets to automatically glide under gravity from the loading face at the rear to the picking face at the front. As each front pallet is removed, the next automatically advances into position.

This architecture enforces a strict First-In, First-Out (FIFO) rotation without any manual intervention, making it especially valuable for perishable goods, pharmaceutical stock, or any product with a use-by or expiry date.

• Access: Sequential FIFO only (front pallet auto-advances on removal)
• Density: High (deep lanes, fewer aisles)
• Best for: Cold storage, food, beverage, and pharmaceutical operations where FIFO is a regulatory requirement

5. Push-Back Racking

Push-back racking stores pallets on a series of nested carts that ride on inclined rails. When a new pallet is loaded at the front, it physically pushes the existing pallets backward along the rails. When the front pallet is removed, gravity brings the remaining pallets forward automatically.

This system operates on a Last-In, First-Out (LIFO) principle and typically accommodates 2–5 pallets deep per lane, offering considerably higher storage density than selective racking without the forklift-entry risks of drive-in systems.

• Access: Front-face LIFO only
• Density: High (2–5 pallets deep, no forklift entry required)
• Best for: FMCG, ambient grocery, and liquor distribution especially in high-cost metro warehouses in Sydney and Melbourne

6. Radio Shuttle Racking

Radio shuttle racking pairs a conventional rack structure with a battery-powered shuttle carrier that travels along the rails inside each lane, autonomously placing and retrieving pallets under operator instruction via a remote control or WMS integration.

This system delivers the highest storage density of any conventional racking configuration, eliminates the need for forklifts to enter the rack structure entirely (improving safety), and can support both LIFO and FIFO depending on system configuration.

• Access: Configurable LIFO or FIFO
• Density: Highest of all conventional systems
• Best for: High-throughput DCs, automated cold stores, and large-volume operations widely adopted by Australian grocery, pharmaceutical, and 3PL operators.

Pallet Racking Structure and Components

Pallet racking consists of upright frames, load beams, and supporting accessories that create safe and efficient storage levels for palletized goods. Components such as decking, anchors, and protectors improve stability and safety, while bays and aisles ensure organized warehouse operations.

Primary Structural Components

• Upright Frames (Uprights): Upright frames are vertical steel assemblies consisting of two columns connected by horizontal and diagonal bracing. They determine the overall height of the racking system and transfer loads safely to the warehouse floor.
• Load Beams: Load beams are horizontal structural members that connect to upright frames, creating storage levels for pallets. They are designed to carry the weight of stored goods and distribute loads evenly throughout the racking structure.
• Baseplates (Footplates): Baseplates are steel plates fixed to the bottom of each upright column. They help distribute the rack load across the floor surface and provide secure anchoring points for the entire structure.
• Anchors: Anchors are heavy-duty bolts installed through the baseplates into the concrete slab. They stabilize the racking system, preventing movement, uplift, or overturning during operation.

Supporting Accessories

Several accessories are commonly used to enhance the safety, stability, and functionality of pallet racking systems.

• Wire Mesh Decking: Wire mesh decking is installed across load beams to create a stable storage surface. It improves safety by preventing loose items from falling and allows water penetration for fire sprinkler effectiveness.
• Pallet Support Bars: Pallet support bars are steel reinforcements positioned perpendicular to the load beams. They provide additional support for non-standard, damaged, or lightweight pallets and reduce the risk of pallet collapse.
• Row Spacers: Row spacers connect back-to-back rack rows, maintaining consistent spacing and improving the overall structural rigidity of the installation.
• Wall Ties: Wall ties are brackets used to secure single rack rows to adjacent warehouse walls, providing additional stability where required.

Structural Safety and Layout Components

• Bay: A bay is the storage section created between two adjacent upright frames. It represents the basic storage unit within a pallet racking system.
• Aisle: An aisle is the designated access pathway between rack rows, allowing forklifts and warehouse personnel to move safely and efficiently.
• Beam Safety Clips (Locking Pins): Safety clips are locking devices installed on beam connectors to prevent accidental beam dislodgement caused by forklift impact or vibration.
• Column Protectors (Post Guards): Column protectors are floor-mounted steel guards installed around rack uprights. They absorb forklift impacts and help prevent damage to critical structural components.
• Load Signs (Load Capacity Plaques): Load signs display the maximum permissible load capacity for each beam level and rack bay, ensuring safe warehouse operation and compliance with safety regulations.
• Shims: Shims are steel leveling plates placed beneath baseplates to compensate for uneven floor surfaces, ensuring proper rack alignment and load distribution.

>> Read more: Heavy Duty Racking – Specifications, Types and Applications

Pallet Racking Safety Standards in Australia

Pallet racking systems in Australia must comply with AS 4084:2023, the national standard governing the design, installation, operation, and maintenance of steel storage racking. Compliance with this standard helps ensure workplace safety, protects inventory, and minimizes the risk of structural failure.

Key requirements include:

• Annual Racking Inspections: A qualified and competent person must inspect the racking system at least once every 12 months to identify damage, overloading, or structural defects.
• Safe Working Load (SWL) Signage: Each rack installation must display clear load capacity signs showing the maximum allowable load per beam level, bay, and rack structure.
• Impact Protection Measures: End frames exposed to forklift traffic must be adequately protected. Corner post protectors with a minimum height of 400 mm are typically required to reduce damage from accidental impacts.
• Seismic Design Compliance: In regions where seismic considerations apply, racking systems must be designed in accordance with AS 1170.4 to withstand earthquake-related forces.
• Controlled Repairs and Modifications: Any structural repair, relocation, or reconfiguration of the racking system should be approved by the manufacturer or a qualified structural engineer to ensure load capacities remain compliant.
• Routine Internal Inspections: Warehouse personnel should perform regular visual inspections to identify common safety issues such as damaged uprights, missing safety locks, loose anchors, or bent beams before they become serious hazards.

Vinatech Australia: Industrial Warehouse Racking – Warehouse Shelving Solutions

• Website: https://vinatech.com.au/
• Phone number: 0406 916 355
• Email: info@vinatech.com.au
• Address: 34 Paramount Bvd, Cranbourne West VIC 3977

FAQ about Pallet Racking