Pallet Racking Systems | 6 Types for Australian Warehouses

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. Each system offers a different balance between storage density, pallet accessibility, stock rotation and handling requirements.

1. Selective Pallet Racking

Selective pallet racking is the most flexible option for warehouses that need direct access to a wide range of SKUs, making it one of the most widely used pallet storage systems in Australia. Unlike high-density systems that require pallets to be moved before reaching the stock behind them, Selective racking provides direct access to each pallet position.

Each pallet sits in its own individual lane and can be accessed by a standard counterbalance or reach truck. This allows warehouse teams to pick, replenish and conduct cycle counts on individual SKUs 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 systems designed to maximise pallet storage by reducing the amount of aisle space required. Instead of operating between conventional rack rows, forklifts enter the storage lanes to place or retrieve pallets.

• 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 provides higher storage density than Selective racking while retaining relatively straightforward pallet handling and warehouse access. The system places pallets two rows deep on each side of an aisle, increasing the number of storage positions available within the same aisle footprint.

The front pallet must be retrieved before the rear pallet can be accessed. As a result, the system sacrifices some direct accessibility in exchange for greater storage capacity. A double-deep reach truck equipped with a telescopic fork attachment is typically required to position and retrieve pallets stored in the rear position.

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 Racking

Pallet flow racking is designed for warehouses that require high-density storage combined with consistent First-In, First-Out (FIFO) stock rotation. The system uses roller or wheel tracks set on a slight incline so pallets move automatically from the loading side towards the picking face.

As the front pallet is removed, gravity moves the next pallet into position. This creates an organised product flow while reducing the need for manual repositioning.

• 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 provides high-density LIFO storage while allowing forklift operations to remain outside the rack structure. Pallets are stored on nested carts or carriers positioned on inclined rails, allowing newly loaded pallets to push existing pallets further back into the lane.

When the front pallet is removed, the remaining pallets move forward under gravity. Depending on the rack configuration, lanes can typically accommodate multiple pallets in depth.

• 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. Shuttle Racking System

Shuttle racking system provides high-density LIFO storage while allowing forklift operations to remain outside the rack structure. Pallets are stored on nested carts or carriers positioned on inclined rails, allowing newly loaded pallets to push existing pallets further back into the lane.

When the front pallet is removed, the remaining pallets move forward under gravity. Depending on the rack configuration, lanes can typically accommodate multiple pallets in depth.

• 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.

Read more: 7 Types of Industrial Warehouse Racking and Shelving Systems

Comparison of Pallet Racking Systems

Each pallet racking system offers different advantages in terms of storage density, pallet accessibility, stock rotation and forklift requirements. Compare the key features below to identify the most suitable solution for your warehouse operations.

Pallet Racking Structure and Components

A pallet racking system depends on a combination of structural components and safety accessories to support pallet loads, maintain rack stability and protect the installation during daily warehouse operations. Selecting the correct components is essential for achieving the required load capacity and maintaining safe, reliable performance.

Primary Structural 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.

• Upright: The primary vertical frame that supports the entire pallet racking structure and transfers loads safely to the floor.
• Beam Bar: Horizontal beams that connect uprights and support pallet loads across each storage level.
• Bracing Bar: Reinforcement members that increase frame stability and improve structural rigidity.
• Support Bar: Additional supports that strengthen beams and provide extra stability for pallets or decking.
• Column Protector: Steel guards installed at the base of uprights to minimise damage from forklift impacts.
• Base Plate: Anchor plates that secure the uprights to the concrete floor, ensuring maximum stability.

Supporting Accessories

Several supporting accessories are commonly used to improve the safety, stability and functionality of pallet racking systems, including Support Bars, Connecting Bars, Foot Bases, Foot Base Covers, Single Crash Barriers and Double Crash Barriers.

• Support Bar: Installed between beams to provide additional support for pallets, wire mesh decks or heavy loads, helping improve load distribution and beam stability.
• Connecting Bar: Connects adjacent racking frames to enhance overall structural rigidity and maintain proper rack alignment.
• Foot Base: Heavy-duty steel base plate that anchors the upright securely to the concrete floor, ensuring maximum stability and safe load transfer.
• Foot Base Cover: Protective cover fitted over the foot base to improve appearance and help protect anchors from dust, debris and minor impacts.
• Single Crash Barrier: Floor-mounted steel barrier designed to protect individual rack uprights from accidental forklift collisions, reducing structural damage and maintenance costs.
• Double Crash Barrier: Heavy-duty protective barrier that safeguards two adjacent rack uprights, providing enhanced impact protection in high-traffic warehouse areas.

Read more: Automated Warehouse: Benefits, Systems and Implementation

Applications of Warehouses Pallet Racking

Pallet racking systems are widely used across a variety of industries to improve warehouse storage capacity, streamline inventory management and support efficient material handling. Whether storing fast-moving consumer goods or heavy industrial products, the right pallet racking solution helps businesses maximise available space while improving operational productivity.

• Logistics, 3PL & Distribution: Ideal for logistics providers, distribution centres and wholesale warehouses handling high pallet volumes, diverse inventories and frequent inbound and outbound operations.
• Retail & E-commerce: Supports large SKU ranges, fast order picking and efficient inventory management, making it ideal for retail distribution centres and e-commerce fulfilment warehouses.
• Food, Beverage, Cold Storage & Pharmaceuticals: Supports FIFO or LIFO inventory management while maintaining product quality for food, beverages, dairy products, pharmaceuticals and other temperature-sensitive goods stored in refrigerated environments.
• Manufacturing & Automotive: Provides organised storage for raw materials, work-in-progress (WIP), finished products, automotive parts and industrial components, helping improve material flow and production efficiency.
• FMCG & Consumer Goods: Enables rapid stock replenishment, efficient pallet handling and high inventory turnover for fast-moving consumer goods and large-scale distribution operations.
• Building Materials & Heavy Industry: Designed to safely store heavy, bulky and oversized palletised products while making full use of available warehouse height and storage capacity.

Warehouse Pallet Racks Standards in Australia

Warehouse pallet racks in Australia Srandrs 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.

Whether you choose Selective, Drive-In, Double Deep, Pallet Flow, Push-Back or Shuttle racking, the final configuration should match your warehouse layout, pallet dimensions, SKU profile, stock rotation requirements and handling equipment.

Vinatech Australia provides customised pallet racking solutions designed around specific warehouse requirements, including layout planning, rack configuration and high-density storage solutions. Contact the Vinat

Vinatech Australia: Smart Warehouse & Pallet Racking Solutions

• Website: https://vinatech.com.au/
• Phone number: 0485 083 868
• Email: info@vinatech.com.au
• Address: 34 Paramount Bvd, Cranbourne West VIC 3977