A good racking layout makes a warehouse faster, safer and easier to expand. A poor one wastes space and slows every pick. These are the steps we recommend when planning a layout.
1. Measure the building
Start with the usable floor area, the clear height under the lowest obstruction, column positions, doors and any sprinklers or lighting that limit how high you can store. Accurate measurements prevent expensive changes later.
2. Understand your stock
List your pallet sizes and weights, how many product lines you hold and how quickly each one moves. Fast-moving items should sit where they are easiest to reach. Heavy items should sit on the lower levels.
3. Choose the right system
Different systems suit different stock. Selective racking gives access to every pallet, double deep racking raises density for uniform stock, and heavy duty racking carries heavier loads. If you need more levels in the same footprint, consider multi-tier racking.
4. Set aisle widths for your forklift
Aisle width depends on the forklift or truck you use. Narrow aisles store more, but only suit trucks designed for them. Always leave enough room for safe turning and for pedestrians where they work near trucks.
5. Plan for safety
Leave clear routes, mark traffic zones and protect uprights from impact with column guards and row spacers. The UK Health and Safety Executive offers practical guidance on warehousing and storage.
6. Allow for growth
Choose a modular system so you can add bays later. Our technical services team can help you plan the layout and install it. When you are ready, contact us for a quotation.
Common layout mistakes
- Aisles that are too narrow for the trucks you use, which slows work and raises the risk of damage.
- Slow movers near the dispatch area, forcing staff to walk past them all day.
- No space for future growth, so any extension means rearranging the whole warehouse.
- Forgetting loading and unloading space near doors and docks.
A simple planning checklist
Before you order, check that you have the building dimensions, a list of pallet sizes and weights, the forklift type, expected stock growth and the location of doors, columns and services. With these, a supplier can design a layout that works from day one. Learn more about our pallet racking options or ask for a site visit.