The right pallet racking types make it easier to access items, lower manual handling, and boost safety in operations. Poorly designed layouts often lead to unnecessary travel time, misplaced pallets, and congestion. Racking systems, when set up based on Health and Safety Executive (HSE) guidance, help keep order, protect workers, and cut down on downtime.
Efficient warehouse design underpins safe and productive operations. The UK Warehousing Association states that the sector has grown by 61% since 2015. Therefore, it’s worth prioritising a fully designed, compliant racking solution no matter where you are in the UK.
Each of our systems is engineered to support clients in meeting both safety and productivity goals.
The 5 Main Pallet Racking Types for Your Warehouse
Selecting the correct configuration begins with a single, straightforward step. First, we must understand how each racking type contributes to storage performance. All systems can support palletised loads. However, the advantages vary based on product turnover, available space, and access requirements.
1. Selective Pallet Racking
This system offers direct access to every pallet and remains the most common configuration in UK warehouses. It supports a wide range of SKUs and frequent picking cycles, making it ideal for eCommerce and distribution facilities. This setup is still popular in UK distribution centres because it’s adaptable. The UK warehousing sector is growing at a rate of 5.6% per year and is expected to reach £36.3 billion by 2024-25. This growth is primarily driven by the need for ecommerce to have flexible storage solutions.
2. Drive-In Racking
Designed for high-density storage, this system minimises aisle space and increases cubic capacity. Forklifts enter the structure to place or retrieve pallets. This makes it well-suited for bulk goods and First-In, Last-Out (FILO) operations, such as cold storage or seasonal stock.
3. Push-Back Racking
This semi-dynamic system uses gravity-fed rollers or carts. Pallets move forward automatically when one is taken away. It delivers moderate density and keeps access simple. This enhances efficiency for multi-SKU warehouses with steady stock movement.
4. Pallet Flow Racking
Also known as dynamic flow or FIFO racking, this design uses inclined roller beds to ensure automatic stock rotation. It works well for operations with perishable or date-sensitive items. This helps lower waste and enhance picking accuracy.
5. Cantilever Racking
This open-front system is designed for handling long or irregular loads, such as timber, piping, or sheet metal. It gives clear access and flexibility. Many in manufacturing and construction use it, as load sizes and shapes often vary.
Each setup must meet the load, spacing, and safety criteria set by the Storage Equipment Manufacturers’ Association (SEMA). Professional assessment ensures compliance, stability, and operational efficiency. SEMA collaborates with the HSE to create guidance on racking installation and inspection. This helps UK businesses comply with safety laws, such as the Provision and Use of Work Equipment Regulations 1998 (PUWER).
How the Right Pallet Racking System Improves Warehouse Efficiency
The layout and design of a racking system directly affect how efficiently a warehouse operates. Wider aisles, clear access routes, and smart load placement facilitate faster movement, conserve energy, and enhance safety in handling.
Well-designed pallet racking types support key operational goals:
- Clear aisles and strategically positioned racks reduce bottlenecks and travel time.
- Multi-tier or high-bay racking boosts vertical storage. This helps save on relocation and facility expansion costs.
- Structural racking systems, combined with impact protection and regular inspections, reduce collision risks and meet HSE warehousing guidance.
Ongoing inspection is a legal and safety requirement under the PUWER. Our routine racking inspections identify damage or overloading before it impacts operational performance.
Choosing the Best Pallet Racking Type for Safe, Efficient Operations
No two facilities operate in the same way. The ideal racking configuration depends on the load weight, product volume, and the type of handling equipment. A careful approach ensures that the selected system strikes a balance between efficiency and safety.
When comparing pallet racking types, several considerations guide decision-making:
- Fast-moving SKUs are best suited for Selective or Push-Back Racking, which provides direct access.
- Drive-In or Pallet Flow systems increase capacity for bulk storage and reduce unused space.
- Compatibility with forklift dimensions and reach height is essential for safety and efficiency.
- Modular systems support expansion and changing stock demands.
Regular racking maintenance and repairs to your equipment help it last longer. It also ensures compliance with BS EN 15635, the British Standard for steel static storage systems. Where there are risks of damage or collision, racking impact protection provides an extra layer of safety. It helps prevent downtime and keeps staff safe from harm.
Integrating Mezzanine Floors & Racking for Smarter Storage Solutions
Using pallet racking with mezzanine flooring is a smart way to boost warehouse space. This approach avoids the high costs of expanding the building. The 2024 UKWA Report by Savills shows that the UK warehousing market has grown by 22% since 2021, reaching nearly 690 million square feet. Warehouse dimensions are also increasing. The development of facilities exceeding 1 million square feet has increased by 345% over the past decade. The benefits of mezzanine systems enable businesses to maximise this vertical capacity without costly building extensions.
Adding a mezzanine floor to the current racking helps create clear work zones. These can include packing, administration, or product assembly areas. This layout separates pedestrian and forklift activity, improving both workflow and safety.
We design and install racking systems supported by mezzanines. These meet UK Building Regulations and SEMA’s codes of practice.
Each of our projects are planned for structural integrity, safe load distribution, and compatibility with:
- Lighting
- Fire protection
- And ventilation systems
For examples of how this integrated approach improves performance and safety, review our case studies.
Expert Pallet Racking Design Smartens Your Warehouse
Warehouse performance depends on how efficiently space and processes are managed. The right pallet racking types boost capacity, safety, and stock visibility. They also meet UK safety standards, including those of HSE and SEMA. Warehouses can boost throughput and reliability by matching product flow with equipment use and load needs.
Every facility deals with various operational challenges. These range from increasing order volumes to the need for faster delivery times. Yet a tailored racking design from First Floors addresses these challenges and protects the long-term value of the system. For more insights, check out our news section. You’ll find updates on racking standards, safety laws, and warehouse best practices.
Call 01789 764172 or schedule a consultation to maximise safety, efficiency, and space utilisation.