Warehouse racking: key facts
- HSE describes racking as a framework of fixed or adjustable design that supports loads, generally without shelves, and says it gives considerable space advantages over floor storage (HSG76, paragraph 631).
- Racking should only be installed by competent people following the manufacturer's instructions, on sound, level floors able to take the point load at each base plate (HSG76, paragraph 634).
- Every run should carry a clear load notice showing the maximum load and load configuration, and those limits should never be exceeded.
- Racking should not be altered (for example by welding) or have parts removed without consulting the manufacturer. Moving the first or second beam from the bottom is normally the most critical change.
- HSE guidance says a nominated person responsible for racking safety should arrange visual inspections weekly or at other regular intervals based on risk, with an expert inspection at intervals of not more than 12 months.
- Damage is graded green, amber or red. Red means offload and isolate straight away; amber damage should be redesignated red if it isn't repaired within four weeks.
- Free-standing racks (not fixed to the floor) should not be used where lift trucks, order pickers or other mechanical handling equipment work.
- Warehouse Racking Hub is an independent guide. We don't design, supply, install or inspect racking ourselves.
What is warehouse racking?
Warehouse racking is a steel framework of upright frames and horizontal beams (or arms) that supports pallets and other loads above the floor. HSE's warehousing guide describes it as a framework of fixed or adjustable design that supports loads generally without the use of shelves, usually named after what it stores, such as pallet racking, tyre racking or drum racking.
The word gets used loosely, so it's worth separating three things that are often bought together:
| What it is | How goods go on it | Typical use |
|---|---|---|
| Racking | Pallets or long loads placed by lift truck, resting on beams, rails or arms | Pallet storage, bulk stock, long and awkward items such as timber, steel and pipe |
| Shelving | Cartons, boxes and loose items placed by hand on shelves or decks | Small parts, picking stock, archive boxes, stores and stockrooms |
| Mezzanine floors | A raised steel floor inside the building, reached by stairs, with goods lifted up by pallet gate, lift or conveyor | Extra storage or picking space, offices or production space above the warehouse floor |
Most warehouses end up with a mix: pallet racking for full pallets, shelving or carton flow for picking, and sometimes a mezzanine to use the height above. The right mix depends on what you store, how fast it moves, and how it's handled.
A few terms come up again and again in quotes and inspection reports. These are the meanings HSE uses in its warehousing guide (which takes them from the storage industry's own glossary):
- Upright frame: two or more uprights joined by bracing.
- Beam: the horizontal load-carrying member, with a connector at each end that locks into holes in the upright.
- Bay: the space between two frames. A run is a series of bays joined end to end.
- Double-sided run: two runs built back to back, joined by run spacers.
- Aisle: the space that gives access to the racking. A gangway is for moving through and doesn't give direct access to the racking.
Which type of racking suits your stock?
Adjustable pallet racking lets you reach every pallet individually, so it suits a wide range of products. Dense systems such as drive-in, push-back and pallet live storage hold more pallets in the same floor space but give up direct access to each one, so they suit lots of pallets of the same product. Mobile racking saves aisles, and cantilever racking holds long loads.
The biggest choice is the trade-off between selectivity (can you reach any pallet without moving another?) and density (how many pallets fit in the space?). HSE's warehousing guide lists the most common systems, summarised here:
| System | How it works | Access to each pallet | Often suits |
|---|---|---|---|
| Adjustable pallet racking | Upright frames joined by beams; beam levels can be moved up or down | Every pallet individually | Many different products, mixed stock, general warehousing |
| Drive-in / drive-through | Pallets stored two or more deep on rails; the truck drives into the lane (drive-in reverses out; drive-through can exit the other side) | Only the front pallet in each lane | Large quantities of the same product |
| Push-back | A block of storage in depth, loaded and picked from the front; pallets are pushed back as new ones go in | First in, last out; one aisle | Several pallets of each product, pallets only |
| Live (flow) storage | Goods travel from a loading face at the back to a picking face at the front, by gravity or powered conveyor | First in, first out; two aisles | Date-coded stock; pallets, boxes or containers |
| Mobile racking | Racking on movable bases that run on rails, so aisles open where needed; powered, manual or mechanically assisted | Every pallet, once the aisle is opened | Maximum storage where access speed matters less, such as cold stores |
| Cantilever racking | Arms (fixed or adjustable) sticking out from upright columns, with no front uprights in the way | Every load | Timber, steel, pipe, sheet materials |
Within these, there are many variations: narrow aisle and very narrow aisle layouts that use specialist trucks to fit more racking into the floor, double-deep racking, and shuttle systems. The pallet racking guide explains the most common system in detail.
What do you need to know before asking for racking quotes?
Before asking for quotes, gather the size and maximum weight of your pallets or loads, how many product lines and pallet positions you need now and in future, the type of truck and how high it lifts, the building's clear height, column positions, doors and sprinklers, and anything you know about the floor slab.
Good quotes start from good information. If two suppliers design around different assumptions, you can't compare their prices. Use this as your brief:
Racking brief checklist
- Loads: pallet type and size, the height of a loaded pallet, the heaviest pallet you'll store (not the average), and any overhang. HSE guidance says the weight of each palletised load should be established before it's put in the racking, unless the racking is designed for the heaviest load you handle.
- Stock profile: number of product lines, pallets per line, how fast each line moves, and whether you need first in, first out.
- Quantity: pallet positions or shelf space you need now, and in two to five years.
- Trucks: the type of lift truck (or the type you plan to buy), its lift height and the aisle width it needs. Aisle width depends heavily on the truck.
- Building: a floor plan with columns, doors, loading bays, fire exits, lighting, heaters and sprinkler heads, and the clear height to the lowest obstruction.
- Floor: any drawings or surveys of the slab, its thickness and condition. Racking needs a sound, level floor that can take the point load under each base plate.
- Operations: where goods come in and go out, picking areas, pedestrian routes and anything that has to stay clear.
- Existing kit: if you're reusing or adding to racking, the manufacturer, the load notices and the latest inspection report.
Ask every supplier to quote against the same brief, and to say what's included: design and drawings, load notices, floor fixing, beam locks, decking, protection, installation, removal of old racking and sign-off. The pallet racking cost guide explains how to compare quotes line by line.
What does HSE guidance say about installing racking?
HSE's warehousing guide (HSG76) says racking should be installed by competent people following the manufacturer's instructions, on sound, level floors that can take the point loads, fixed to the floor where lift trucks are used, with beam connector locks fitted and a clear load notice on each run.
HSE's guide Warehousing and storage: A guide to health and safety (HSG76) sets out the basic principles for safe installation. In plain English:
- Competent installers. Racking should only be installed by competent people following the manufacturer's instructions. HSG76 mentions SEIRS, the Storage Equipment Installers Registration Scheme run by SEMA, the storage equipment industry's trade association. It's a voluntary scheme; SEMA itself says there's no mandatory qualification for racking installers in the UK.
- A floor that can take it. Racking should stand on sound, level floors able to withstand the point load at each base plate. A heavily loaded run puts a lot of weight through a small plate, so an unknown slab is worth checking before you design.
- Fixing. Where lift trucks or other handling equipment are used, racking should be fixed to the floor. HSG76 gives minimum rules based on the height-to-depth ratio of the rack, and many suppliers fix every upright. Drive-in and drive-through racking should always be floor-fixed in line with the manufacturer's instructions.
- Back-to-back runs should be connected and spaced with run spacers.
- Beam connector locks should always be fitted, so a lift truck can't knock a beam upwards out of its slots.
- Aisles wide enough for the trucks to manoeuvre easily. The width depends on the type of truck.
- A load notice securely fixed to the racking, stating the maximum load and any load configurations. The limits on it should never be exceeded.
After installation, the same guidance warns against changing the racking without checking. Racking should never be altered (for example by welding) or have parts removed without first consulting the manufacturer. Before moving beams, you need to know the design limits of the new layout and update the load notice if needed. Moving the first or second beam from the bottom is normally the most critical change and always needs a check of the rack's carrying capacity.
HSG76 also says racking must not be used as access equipment unless it's designed for that: climbing racking is prohibited.
How often does warehouse racking need inspecting?
HSE guidance describes three levels: damage reported straight away by anyone who sees it, visual inspections weekly or at other regular intervals based on risk (with a written record), and an expert inspection by a technically competent person at intervals of not more than 12 months, with a written report.
Racking is made from relatively lightweight steel, and HSE notes that any damage reduces its load-carrying capacity: the greater the damage, the less its strength. That's why inspection is a routine, not a one-off.
| Level | Who | How often (HSG76) |
|---|---|---|
| Immediate reporting | Any employee who sees damage or a safety problem reports it to the person responsible for racking safety | Straight away |
| Visual inspection | Arranged by the person responsible for racking safety, with a formal written record | Weekly or at other regular intervals based on risk assessment |
| Expert inspection | A technically competent person: a trained specialist in your own organisation, a specialist from the rack supplier, or an independent qualified rack inspector | At intervals of not more than 12 months, with a written report and proposed actions |
Damage is usually graded using a traffic-light system from HSG76:
- Green: within acceptable limits. Record it and look at it again at future inspections.
- Amber: hazardous damage that needs repair as soon as possible. Once the load is off, don't reload until it's repaired. If it isn't repaired within four weeks, it should be treated as red.
- Red: very serious damage. Offload and isolate that area immediately, and keep it out of use until it's repaired, usually by replacing the damaged part.
SEMA runs a voluntary qualification for expert inspectors, the SEMA Approved Rack Inspector (SARI) scheme. The racking inspection guide covers what an inspector checks, what the report should contain and how to choose one.
When is a mezzanine floor the better answer?
A mezzanine floor adds a second level inside the building, so it suits operations that need floor space for people or hand-picked goods (picking, packing, offices, light production) rather than more pallet positions. If the extra space is for full pallets, higher or denser racking is often the first thing to look at.
Racking uses the height of a building for pallets. A mezzanine uses it for floor space. That makes mezzanines a good fit for:
- picking and packing areas for small items, with shelving on the upper level
- offices or staff areas above the warehouse floor
- light assembly, kitting or returns processing
- multi-level picking between racking runs. HSG76 describes mezzanine pick levels fed by lift truck from the other side, and says a shelf should be fitted at the upper pick location so no one can fall into the gap when a pallet is removed, with a protective rail at the lower level
Mezzanines are usually more involved than racking because people work on them. They need safe stairs, edge protection and a safe way to load goods on and off, and the design has to take account of fire safety and escape routes. In England, a mezzanine floor will often involve building regulations; the mezzanine floor building regulations guide explains when and what's checked. The mezzanine floors guide covers uses, loads, access and planning.
What affects the cost of warehouse racking?
The cost of racking depends mostly on the number of pallet positions, the height and the weight each level has to carry, plus decking, protection, floor fixing, design, installation and access. Quotes that look cheaper per pallet position often leave some of these out, so compare like for like.
We don't publish "typical" prices: there's no reliable public source for them, and prices depend heavily on steel costs, specification and site conditions. What we can tell you is what moves the price, so you can read quotes properly:
- Number of pallet positions and how they're arranged (bays, levels, beam lengths).
- Height and load: taller frames and heavier pallets need heavier-duty uprights and beams.
- The system type: dense and moving systems (drive-in, push-back, live storage, mobile, shuttle) cost more per position than standard adjustable racking but can fit more positions into the space.
- Extras: decking (mesh, timber or steel), upright and end-of-run protection, signage and load notices.
- Floor: fixing, any survey, and remedial work if the slab isn't suitable.
- Design and installation: drawings and calculations, labour, access equipment, out-of-hours working, and removing old racking.
- Ongoing costs: inspections, repairs and replacing protection after impacts.
The pallet racking cost guide shows how to work out cost per pallet position from a quote, why it can mislead, and a worked example using clearly labelled example figures.
How do you choose a racking supplier, installer or inspector?
Check that the company has the right insurance, works to recognised design standards, has a quality management system, gives clear advice on loading, and uses trained installers and inspectors. Ask for the design basis and load data in writing, and compare quotes against the same brief.
Anyone can call themselves a racking company. These questions help you separate the careful from the careless (several come from the questions SEMA suggests asking):
Questions to ask
- What insurance do you hold, and can we see the certificates?
- Which design standard is the racking designed to? (In the UK, SEMA says the industry-accepted standards are its own design codes or the European standard EN 15512.)
- Will you supply drawings, load data and load notices for every run?
- Do you have a quality management system?
- Who will install it, and what training do they have? Are they registered under SEIRS?
- Will the racking be floor-fixed, and has anyone checked our floor can take the loads?
- What's included: decking, protection, beam locks, removal of old racking, sign-off?
- For an inspector: what does the inspection cover beyond listing damage, what does the report look like, and is the inspector SARI qualified?
SEMA also runs an approved member scheme, in which members are independently audited (SEMA says audits are repeated every five years). Membership of any trade body is voluntary, so treat it as one useful signal rather than a legal requirement.
How does Warehouse Racking Hub work?
Warehouse Racking Hub is an independent guide. If you fill in the form, we pass your enquiry to one storage systems specialist from our partners that covers your area, chosen by your postcode and what you need. The introduction is free and there's no obligation.
We write plain-English guides to help businesses plan storage and keep it safe. We don't design, supply, install or inspect racking or mezzanine floors ourselves, and we don't give advice.
- You tell us what you need: new racking, a mezzanine floor, an inspection, repairs or moving existing racking, with a rough idea of size and timescale.
- We pass it to one specialist from our partners that covers your postcode. Your details go to one partner only.
- They contact you to talk it through, visit if needed, and quote. Prices and terms are agreed directly between you and them.
We may be paid by the partner for the introduction. That doesn't change what you pay, and you're under no obligation to go ahead.
Related guides
Warehouse racking: frequently asked questions
What is the most common type of warehouse racking?
Adjustable pallet racking, sometimes called selective racking, is the most widely used. It uses upright frames and horizontal beams, the beam levels can be moved, and every pallet can be reached individually.
Does warehouse racking have to be inspected by law?
Health and safety law requires work equipment to be maintained and kept safe, and HSE's warehousing guide (HSG76) recommends regular visual inspections plus an expert inspection at intervals of not more than 12 months. Following that guidance is the usual way businesses show they are managing racking safely.
Who can carry out a racking inspection?
HSE guidance says the expert inspection should be done by a technically competent person. That could be a trained specialist in your own organisation, a specialist from the racking supplier, or an independent qualified rack inspector.
What does red, amber and green mean on a racking inspection?
Green means damage within acceptable limits that just needs watching. Amber means hazardous damage that needs repair as soon as possible, and it should be treated as red if not repaired within four weeks. Red means very serious damage: offload and isolate that area immediately until it is repaired.
Can I move the beams on my pallet racking?
Only after checking the design limits of the new layout, usually with the manufacturer or supplier, and updating the load notice if needed. HSE says moving the first or second beam from the bottom is normally the most critical change and always needs a check of the rack's carrying capacity.
Does pallet racking need to be bolted to the floor?
HSE guidance says free-standing racks should not be used where lift trucks or other handling equipment work, and sets minimum floor-fixing rules based on the rack's height-to-depth ratio. Many suppliers fix every upright.
Is SEMA membership a legal requirement?
No. SEMA is the storage equipment industry's trade association. Its installer and inspector schemes and approved member scheme are voluntary, but they can be a useful sign that a company works to recognised standards.
Do I need building regulations approval for a mezzanine floor?
In England a mezzanine floor will often involve building regulations, particularly for fire safety, escape and stairs. Our mezzanine floor building regulations guide explains when approval is needed and what is checked.
How much does warehouse racking cost?
It depends on the number of pallet positions, height, loads, the type of system, extras such as decking and protection, and installation. We don't publish typical prices because there is no reliable public source, but our cost guide explains how to compare quotes.
Do you install racking?
No. Warehouse Racking Hub is an independent guide. If you ask us to, we pass your enquiry to one storage systems specialist from our partners that covers your area.
Sources
We checked the facts on this page against these sources on 12 November 2026: