Pallet racking is a storage system made of vertical frames and horizontal beams that lets warehouses store palletized product above floor level. It’s the foundation of most warehouse racking systems, and pallet racking systems come in several configurations, each suited to different storage, access, and throughput needs. Pallet racking systems are a great way to capitalize on square footage in a warehouse. These systems allow for increased vertical storage, greater mobility, and increased safety on the warehouse floor. Each pallet racking system has its own advantages and each warehouse has its own unique storage needs. When designed and used properly, a pallet racking system allows for increased product flow or storage, both in product variety and depth. For example, systems are geared towards long-term bulk storage while others are created to allow for short-term, high-turnover products.
Commonly used across many industries, selective pallet racking systems can be found in a wide variety of industries. These systems allow for access to each pallet bay but also require forklift access in aisle ways to stock each bay. A selective system is best used within a facility which has a large variety of products but a low turnover of individual products.
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Rack supported structures play double duty. In addition to their use as a storage system, rack supported structures support the building as well. Once the rack structure is built, it will then be covered with walls and/or ceilings to protect the products. By combining the building phases of the building and the racking systems, these structures save time and money. These systems are a great way to create an ideal storage area.
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Pallet flow pallet racking uses gravity to move pallets from a loading side to an unloading side. Due to the way the system moves product, this style is also called gravity flow racks. As a pallet is removed from the unloading side the pallets behind will automatically fill in the front position. This allows for more storage of a single product. The pallet flow system is best implemented in a first-in, first-out system.
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Both drive-in and drive thru pallet racking systems are similar. They allow forklifts to load and unload products from one or both sides of the rack through a system of support rails. Each pallet position is dependent on the position of the other pallets. Drive-in systems have a single entrance, while drive thru systems allow for access on either lane. These systems are best used in high-capacity storage for a product.
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Push back pallet racking systems are great options for warehouses that work with some selectivity of product, but with multiple pallets of each product. This racking system works by using gravity to feed the front of the system with angled rails. Each product lane is independent from other lanes, and these lanes can hold 2 to 6 pallets per lane, allowing for a last-in, first-out product management system.
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Cantilever racking systems allow for the storage of large and awkwardly shaped items. Different from traditional pallet racks, these systems are made from a series of columns with adjustable arms. The construction of these racks means that there is no limit to the length of the stored product. This also means there is the capacity to store a wide variety of lengths, shapes, and weights in the same rack system.
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Carton flow / case picking racking is a great system to increase product flow. These systems use gravity to feed the front of the rack with product loaded from the back side. Carton flow systems are versatile, implementing either a roller lane which acts as a single flow, or on wheel beds which allow for a variety of products to be used. This system works best with case and piece-picking needs.
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Pick module pallet racking systems combine different features of storage, product handling, and shipping systems to make the most efficient system of high-volume case picking and small parts distribution. These systems use a variety of options including pallet racking systems, case flow racks, and conveyor systems. A pick modules system utilizes every option available to create a custom designed system. This provides the best solution for each project.
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Whether buying or selling, DACO can assist you with your used pallet racking system needs. We carefully examine all used pallet racking components, so we ensure the safety of each part before resale. As our inventory of used pallet racking changes from day to day, we may or may not be able to offer an exact match for your replacement needs.
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Pallet racking systems are most efficient when used with proper safety and accessories. Safety of pallet racking systems can be enhanced through different safety accessories both on the racks and separate from the racks. Repeated use of pallet racking requires maintenance and inspection to prevent any problems. If any safety concerns are found, it is important to repair the parts causing concern.
Explore Pallet Rack Repair & SafetyEach pallet racking system offers a different balance of selectivity, storage density, and floor space efficiency. The table below compares DACO’s core pallet racking systems side by side to help you narrow down the right fit before you reach out to our team.
| Pallet Racking System | Best For | Selectivity | Storage Density | Forklift Access |
|---|---|---|---|---|
| Selective Pallet Racking | Facilities with many different SKUs | Full — every pallet directly accessible | Lower | Direct aisle access to every bay |
| Rack Supported Structures | New builds combining racking with the building shell | Depends on the racking configuration used inside | Varies | Varies |
| Pallet Flow (Gravity Flow) Racking | High-volume, first-in-first-out product | Limited — one SKU per lane | High | Load from one end, pick from the other |
| Drive-In & Drive-Thru Racking | High-capacity storage of fewer SKUs | Low — last-in-first-out (drive-in) | High | Forklift enters the rack structure itself |
| Push Back Pallet Racking | Multiple pallets per SKU with some selectivity | Moderate — last-in-first-out per lane | High | Loaded/unloaded from the same aisle |
| Cantilever Rack | Long or irregularly shaped items (lumber, pipe, etc.) | Full access along the arm length | Varies by item length | Open-front access, no upright obstruction |
| Carton Flow & Case Picking | Case- and piece-picking operations | High — organized by SKU on each shelf | Moderate | Gravity-fed to a fixed pick face |
| Pick Module Systems | High-volume, multi-level picking operations | High | High (uses vertical space) | Combination of levels, stairs, and conveyor |
| Used Pallet Racking | Budget-conscious buyers or fast turnarounds | Depends on the racking type sourced | Depends on the racking type sourced | Depends on the racking type sourced |
DACO-supplied racking commonly ranges from 4′ to 40′ high with shelf capacities up to 20,000 lbs, depending on the system and configuration.
Knowing the needs of your warehouse and your company will allow you to create an ideal pallet racking system for your storage needs. These systems are versatile enough to use a combination of systems within the same warehouse and allow for use across a number of different industries. Pallet racks can be combined with other warehouse systems such as conveyors to create optimal product storage, handling, and shipment, saving time and money throughout a facility.
Once your storage rack is installed you might want to consider any number of warehouse safety considerations & accessories, such as pallet rack safety enclosures that help keep goods safely contained within the bays, rack labels which display the beam and rack capacities, and wire decking that allows you to store non-rack supported pallets of goods in a safe and stable manner.
To make the most out of a pallet rack system, it is essential to include all of the proper accessories and safety equipment. Also, inspection and repair of any damaged pallet racks are crucial to ensure proper warehouse safety.
Choosing the right pallet racking system starts with understanding your product mix and how it moves through your warehouse. A few questions can help point you in the right direction:
Every warehouse has its own mix of these factors, and most facilities end up using a combination of systems rather than just one. Talk with a DACO racking expert to walk through your specific operation and get a recommendation tailored to your space.
Pallet racking should be installed according to the system design, manufacturer requirements, applicable rack standards, and local building requirements.
Anchoring and permitting needs can vary based on the rack type, layout, facility, seismic conditions, and jurisdiction. DACO has experience designing and installing pallet racking for projects with seismic and permitting considerations.
Contact DACO to discuss installation and anchoring for your project.
Pallet racking should be inspected regularly for visible damage or changes that could affect its safe use. Common things to look for include damaged or bent components, loose or missing hardware, signs of impact, the condition of load and capacity signage, and the condition of safety accessories such as rack guards and wire decking.
Inspection and maintenance should follow the rack manufacturer’s requirements and recognized industry guidance, such as standards published by the Rack Manufacturers Institute (RMI), rather than a one-size-fits-all schedule. If damage is found, the affected component should be evaluated and addressed before the rack is used again.
DACO’s Pallet Rack Repair, Safety & Accessories team can help inspect, repair, and outfit your existing racking.
As we gain an understanding of your business, we can design and supply an efficient storage system preserving capital on the front en, and increasing profit after implementation.
Storage rack applications are limitless and include both the standard configurations and the custom designed. Commonly supplied products range from 4′ to 40′ high with shelf capacities up to 20,000 lbs. Installations cover North America ranging from Alaska to Mexico and Washington to Florida and Hawaii. Height, aisle width, and capacity all work together to determine the right configuration for your space, and aisle width is typically driven by the type of forklift or material handling equipment used in your facility.
We stock various sizes and gauges of new and used pallet racking beams, uprights, footplates and wire decks, so we can custom design a racking system just for you. Looking specifically for used racking? Visit our Used Pallet Racking page to see what’s currently available — our team can help evaluate fit and compatibility for your specific system.
With so many racking systems to choose from, deciding which one is right for your business can be a challenge. DACO has years of experience helping our customers increase and maximize their storage space by picking the right system for their business. We look forward to partnering with you to help you do just that.
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