Warehouse Racking Systems
Pallet Racking
Pallet racking – the formula for warehouse organisation
Give your operation its strength of character with a space saving pallet racking solution uniquely designed to match your specific needs. The easy way to save space whilst storing high volumes of palletised goods, pallet racking is fundamental to a streamlined operation with reduced running costs and heightened productivity.
With the right pallet racking solution you can reduce the risk of damage to stock, maintain flexibility when storing a variety of products, manage stock control and rotate stock as required, but that’s not all. Using a bespoke pallet racking solution created by WSL your storage facility can be maximised to its full potential with design which will utilise all available floor and height space.
Pallet Racking Solutions Direct From Our Stock
By putting our on-site warehouse space to good use, WSL is better equipped to meet your time-bound needs, easing the frustration caused by supply chain issues wherever we can. Currently WSL stocks many pallet racking components including frame sections, beams, row spacers and column guards. Beyond that we are set to vastly broaden our range of stock with plans for major expansion which are very much underway. We will bring you updates on this as the project progresses and in the meantime WSL will use our current capacities to stock along with our strong supplier relationships to limit time delays to your project as much as possible.
What Is Pallet Racking?
Pallet racking is an independent structure designed to facilitate the storage and handling of palletised goods within a warehouse and is available in a number of different formats to suit different warehouse operations. A bespoke solution using the pallet racking system most suited to your operation is essential to meeting your unique requirements and making significant improvements to your business. Pallet racking comes in a variety of formats, choosing the right system for your storage space is essential and depends upon the items you’re storing and your commercial objectives. Selecting a bespoke solution that meets your unique requirements is essential in making significant improvements to your business.
There are many benefits to using a racking system by WSL. By utilising valuable floor space, building height and volume your storage facility can be maximised to its full potential. By choosing the right racking system for your requirements you can reduce the risk of damage to stock, maintain flexibility when storing a variety of products, manage stock control and rotate stock as required.
The benefits
Types of pallet racking
There are 8 main types of Pallet Racking in use within the UK for the storage of palletised goods.
- Drive-in or Drive-through Racking
- Mobile Racking
- Narrow Aisle Racking
- Very Narrow Aisle Racking (VNA)
- Wide Aisle Racking
- Push Back Racking
- Pallet Live Racking (Flow Racking)
- Double Deep Racking
When it comes to pallet racking, one type does not suit all. Every warehouse has its own unique traits in terms of size, operations, inventory type, flow and speed and all of these can be fully supported with the right pallet racking system. Storing pallets securely is just one of the essential roles of pallet racking because it can also utilise all available space; even up to the ceiling, rotate stock automatically increase speed, streamline the picking process, improve overall productivity and save you time and money. Below we outline the different capabilities of each type of pallet racking system:
Drive-in Drive-through racking
Drive-in or Drive-through Racking – Waste no space with a Drive-in or Drive-through pallet racking system both of which provide high density storage and can utilise up to 85% of your cubic area. They bring an economic advantage to cold store environments looking to reduce energy consumption because the racks are purposely configured to provide high compact storage. Drive-in operates using the First-in Last-out (FILO) method and requires only one working aisle for loading and picking. Drive-through has two working aisles running parallel on the edge of the structure where loading and picking is carried out separately. Drive-through is ideal for perishable goods because it works on a first-in first-out (FIFO) basis, rotating stock automatically.
Wide Aisle racking
Wide Aisle Racking – Also referred to as adjustable pallet racking (APR) this is a highly versatile cost effective system which can be configured to suit your space and operational needs. It will adapt easily at any time to accommodate changes and gives you direct access and requires no specialist handling equipment.
Pallet Live Racking
Pallet Live Racking – Often known as flow racking, pallet live is highly compact and consists of deep running racks and only two aisles at either side. The slightly inclined rollers running the length of the lanes allow use of gravity to transport the pallets once loaded to the picking face at the opposite end. The system uses the FIFO so if you’re looking for a system which will provide automatic stock rotation, speed and maximum use of space, this is an ideal solution.
Push Back Racking
Push Back Racking – A deep storage system consisting of long running lanes similar to that of pallet live racking, however push back racking requires only one service aisle from which pallets are both loaded and retrieved. The push back system uses the FILO (First-in Last-out) flow method so if stock rotation is not a primary focus, but space utilisation and speed is then this could be ideal for your facility
Mobile Racking
Mobile Racking – Use 90% of your floor space for storage with mobile racking which is highly compact and can work on either of the FIFO or FILO methods. Here there is no fixed aisle as the racks sit on a mobile base and access is needed the aisle can be created at the right location by opening the racks either manually or through a powered control. Only one aisle space can be opened at one time so this system would suite low turnover items which require safe storage until picked.
Narrow and Very Narrow Aisle Racking
Narrow Aisle Racking or Very Narrow Aisle Racking (VNA) Where floor space is limited, but there’s plenty of headroom, narrow aisle racking can transform your warehouse by making the most of your cubic space. By installing taller racking and drastically reducing your aisle width you can gain maximisation of both floor and height space and increase storage capacity by utilising the cubic area of your facility. Specialist trucks will be required to navigate the narrow aisle and reach the high racks however, it’s a lucrative investment against long term efficiency and savings gained by stacking high.
Double Deep Racking
Double Deep Racking – The structure itself is no different to wide aisle racking only the racks are positioned back to back. You can double your racks and still gain access from the same aisle and because this is a standard pallet racking system with no additional components it’s a low cost solution
Shuttle Racking
Shuttle Racking – Transport your pallets deep into a compact system along rails using a radio controlled shuttle on which individual pallets are loaded. The system can use both the FILO and FIFO method and can be switched to change methods easily.
How is Pallet Racking Structured?
Pallet racking is structured using a number of component parts, some of which are essential and others are optional whilst some pallet racking systems have component parts that others don’t. The parts are carefully laid out before being assembled by a team of installers who use lifting equipment to help bring the parts together. Pallet racking component parts include:
Pallet racking is structured using a number of component parts, some of which are essential and others are optional whilst some pallet racking systems have component parts that others don’t. The parts are carefully laid out before being assembled by a team of installers who use lifting equipment to help bring the parts together. Pallet racking component parts include:
Frames – Each frame is formed through the assembly of two steel uprights with horizontal and diagonal bracing welded between the uprights. The frames stand vertically between each bay on base plates that are fitted to ensure adequate weight support.
Beams – These steel bars are positioned horizontally between the frames and are fitted to the upright elements using connecting pins designed to secure the beam into place. With a beam fitted to the front of the bay and another to the back, pallet shelves are formed and these support the pallets once placed.
Upright Protectors – Providing a sturdy shield around the bottom of the uprights, these robust guards take the impact of any collisions from moving handling equipment rather than the structure itself.
Decking – Between the beams is a gap which is perfectly fine when storing standard pallets, however decking can be fitted to cover the gap to prevent smaller pallets or loads from falling through. The material used to create decking include timber, steel wire mesh, steel panels and chipboard therefore choosing the right decking type will depend on the items being stored.
Mesh pallet racking protection – Steel or roped mesh fitted to the back of a pallet racking structure is used to increase safety within the warehouse as it prevents any loose items from falling and causing injury or damage.
Pallet stop – Fitted to the rear of the racking a pallet stop will ensure pallets cannot fall from the back of the system if accidentally pushed.
Fork lift truck guide rails – These are used to increase safety when using certain pallet racking systems. When using a drive-in drive through racking system for example the rails are fitted to the outer edge of the lanes to prevent collision as the fork lift truck navigates the structure. Wired guide rails are often used on narrow aisle racking where they are fitted centrally and uses radio transmission to guide the narrow specialist fork lift truck between the rows.
Pallet support rails – Required on drive-in drive-through racking systems, these are used instead of beams to support pallets and enable fork lift trucks to enter the lane without obstruction. The rails run along the length of the lanes and are fitted to the uprights using brackets.
Rollers – Works alongside gravity to transport pallets through the long lanes of the tilted pallet live and push back racking structures.
Shuttle rails – Fitted to the length of the lane to transport a shuttle on which a pallet sits as it’s moved within the lane on a shuttle racking system
Pallet Racking Safety
Pallet racking is a significant structure loaded with high quantities of heavy loads therefore safety is a serious matter. The obligation to protect any persons accessing the area is both moral and legal, whilst the cost to the business in terms of money and reputation could be significant if safety is not prioritised. Although there are many pallet racking accessories designed to help reduce risk and increase safety, its important that you understand the risk factors associated with pallet racking safety and these include:
Handling equipment – Fork lift trucks (FLT) on the move is not an unusual sight in warehouse operations. The FLT goes hand in hand with the pallet racking structure, transporting, picking and loading pallets safely, however the risk of accidental collision is always there. Although hardwearing, the strength of the steel pallet racking structure can be compromised after multiple knocks.
Protection in terms of end of aisle barriers, upright protectors and guide rails can be fitted to protect the structure from bumps and knocks. These robust steel ancillaries are positioned to be on the receiving end of the collision, rather than the structure itself. Manufactured by WSL, we can provide bespoke racking protection solutions that match your exact needs in terms of quantity, style and colour.
Overloading –With your inventory in mind, your bespoke pallet racking system will be designed with a maximum weight load limit which should never be exceeded. Loading too heavily on the pallet shelves can add strain which may result in weakness and even collapse.
To help prevent overloading, operators should be made aware of the structures maximum weight load bearing. Available from WSL, weight load notices, fitted to the structure provide access to this information spontaneously allowing operators to check as they work. These uncomplicated notices stating the maximum weight load capacity are clear and easy to read making them a very worthwhile addition to your structure.
Falling behind with annual rack inspections – It can be easy to misjudge the importance of annual pallet racking inspections and this can result in devastating consequences. Without a rack inspection at least once a year, specific damage or weaknesses that may have gone unnoticed is likely to worsen over time and cause the structure to become unstable or even collapse. Serious injury could be caused as well as damage to inventory, costing the businesses dearly. An annual racking inspection provides assurances that the structure does not pose a risk to anyone working with or near it. The inspections ensure safety is continually maintained by allowing risks to be flagged up and appropriate actions to be taken, so be sure to ensure a rack inspection is included in your yearly calendar!. At WSL our experienced and qualified rack inspectors are extremely thorough and trustworthy and can inspect your pallet racking structure wherever you are in the UK. The inspection involves an assessment of each component, with notes made of any concerns which will be included in the final report. Any areas that pose immediate safety threats will be flagged up to you there and then to allow you to take prompt action in making the area safe.
Lack of staff training – Appropriate and safe use of the pallet racking structure is crucial to ensuring safety which is why operators should be trained on how to use the structure correctly. This will prevent unnecessary damage to the structure and accidents that may cause serious injury. Your team’s ability to spot potential safety risks can also be a huge advantage. By carrying out in-house safety checks periodically between annual rack inspections, huge and very costly incidents can be prevented. WSL can train your operators on how to carry out internal inspections training them on how to spot damage or potential weaknesses and what action they should take.
Our Process
Pallet Racking By WSL
WSL is a Leeds based pallet racking solutions provider who operate throughout the UK. We offer all types of pallet racking and by using our extensive knowledge and experience we can turn the right pallet racking system into an ideal solution, whether you are looking for a completly new system or ways to upgrade your current pallet racking configuration. For large scale projects requiring multiple solutions we offer a turnkey service. As well as the design and implementation of your storage systems, we cover additional needs such as lighting, heating, air-conditioning and sprinkler systems so your time can be spent focussing on other things
Initial Contact
The initial call will be to obtain some basic information, such as the location of the project, the company, contact details and a brief summary of what you are looking for. The advisor will then arrange to meet with you and visit the site in order to discuss more in depth your requirements and how we may be able to help you.
Free Plans And Drawings
After the site survey is complete and we have gathered all necessary information, are able to produce alternative racking layouts to match the warehouse layout with the advantage of the Computer-Aided Design software AutoCAD. This advanced drafting software system allows realistic visualisation your facility once fitted out with your chosen new racking system.
Free Site Survey
A site survey is a crucial part of the design process as it allows us to gain an insight before creating any plans. During the site survey we will inspect the site where the proposed works are to be carried out to ensure the site is safe for the installation of racking and identify any potential problem areas early in the process. We will look at the space you have and after gathering information about your overall operations, flow of goods, goals and budget. We will work with you to achieve the optimal solution for you your operations.
The Installation Process
WSL employ an outstanding team of racking installers who will work closely with you to make the installation as smooth as possible. We are experienced at working to tight deadlines, and can even work through the night where necessary, so usual operations can continue in the day. As a full member of the UK Storage Equipment Manufacturer Association (SEMA), we not only comply with all industry standards for pallet racking installation but are also involved in setting the standards. With an impeccable safety record and a name for quality, with WSL you can be sure that installation will be as efficient and secure as possible.
The Cost of Pallet Racking
When considering the prospect of a new pallet racking system, there are many aspects to consider including the cost. A pallet racking system is a leading storage solution which can shape your industrial building and transform your operation; however the uncertainty of the initial cost can be something of a concern.
WSL can help with any unease regarding cost, simply and easily by understanding your particular requirements before providing the best and most cost effective solution to suit your exact needs, with the aim of saving you time, money and extra work.
We’ll produce a bespoke pallet racking design that will maximise your space, support the needs of your inventory and simplify your operational processes. Through these competences, pallet racking costs can be limited and profitability heightened.
Experienced and efficient we can answer your questions, produce drawings and plans and turn quotes around quickly for you.
Cost Assumptions
There will be many factors taken into account when providing the quotation for your pallet racking. The site survey allows us to provide the most accurate price, after discussing your requirements and advising you on the various options available too you. Please feel free to contact us for a no obligation quotation and free site survey.
In order to provide a rough idea of cost we have had to make some assumptions:
- Pallet weight – 500K.Gs
- Pallet size U.K pallet (1,200X1, 000mm) stored on the 1,200mm face.
- Wide aisle racking assume 6 pallets in height (Including ground floor)
- Narrow aisle racking assume 8 pallets in height (including ground floor)
- Drive in racking assume an economical layout of 8 deep X 5 wide X 4 pallets tall
- Below Prices do not include VAT
- Below prices assume a quantity of at least £10,000.00 of materials have been ordered.
Rough guide prices assume slab quality is good & no spreader plates are required
Due to the current market volatility, we advise you contact our team for accurate pricing.
Pallet Racking Estimates
The following costings are provided as a rough outline and to be taken in light of the assumptions listed. Depending on the type of Pallet Racking, the starting cost per pallet location can vary.
Wide Aisle Racking
Cost per pallet location – from £34.00
Cost to fit upright guards- from £11.00
Cost to fit rack end barriers- from £58.00
Narrow Aisle Racking
Cost per pallet location- from £36.00
Cost to fit upright guards- from £11.00
Cost to fit rack end barriers- from £58.00
Drive In Racking
Cost per pallet location- from £58.00
Protection ancillaries- Included in prices above
Push Back Racking
Cost to fit upright guards- from £11.00
Cost to fit rack end barriers- from £58.00
Shuttle Racking
Cost per pallet location- from £110.00
Shuttle Racking is a difficult to get an average cost for, due to the fact that it is semi automated. Some shuttle systems will require more than one “shuttle” meaning the price per pallet location will increase.
The benefits
Why Choose Pallet Racking?
When you have the right pallet rack system for your storage facility, it will allow your warehouse space to be optimised, allowing you to store the most pallets possible.
A bespoke racking system can maximise the number of pallets you can store.
You can use the full height of your warehouse to avoid wasted space
Designers can calculate the best layout to make the most of the floor space you have available – Read More
There are options for fewer aisles, depending on what you are storing and how often you need to access it.
Use a combination of different racking systems to optimise your space.
Why choose wsl?
What Sets Us Apart
Our dedicated and experienced team will take time to understand your goals and asses your needs. Our extensive market knowledge and practical experience enables us to design and develop a bespoke system that is as unique as your business. Here at WSL we aim to maximise your available space and increase productivity through creating innovative and ‘outside the box’ solutions. Our commitment to excellence, our portfolio and our recommendations provide our customers with confidence in our ability to deliver solutions that are not only superior, but very cost-effective. Our in-house services simplify the process from design to installation by giving you just one port of call. By continuing to remain independent across the whole market we commit to providing our valued customers with the highest quality and – wherever possible – British products, all at competitive prices. We aim to fit our pallet rack systems with as little inconvenience to our clients as possible, using highly experienced fitters overseen by qualified project managers.
Our Accreditations
client stories
Some Case Studies
Our warehouse Racking experience is extensive. Take a look at a very small selection of some of the pallet racking projects we have completed over the years.
Trusted by all
Just Some Of Our Clients
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Our service is completely client-centric. We provide all manufacturer types, as well as fitters, engineers and inspectors; which means that not only can we deliver your entire project from start to finish, but that we can provide a fully bespoke solution for your individual needs. Get in touch to find out more.