Pallet rack systems maximise storage space, supporting efficient organisation and easy access to inventory. But only if they are assembled and anchored correctly.
Knowing how to install pallet racking is critical if you want it to do its job safely, reliably and in compliance with industry standards.
If these systems are set up incorrectly, your business could face costly and devastating outcomes like racking collapse, product loss and even injury to workers. Don’t risk it.
If you’re planning to add a pallet racking system to your facility, we’re here to help you get started. In this general guide*, you’ll find a step-by-step process, plus tips and considerations for installation.
What to know before assembling your pallet racks
Before you learn about how to install pallet racking, it’s important to follow the below steps:
Determine your layout
Whether you’re upgrading your racking system or relocating and reinstalling it, your goal should be to maximise space, improve workflow, and enhance accessibility.
Before installation, it’s essential to assess the available space thoroughly. Measure the floor area and ceiling height, and identify any physical obstructions like overhead beams or pillars.
Then clearly mark where the racking will be placed, and inspect the floor for load-bearing capacity and potential defects.
Understanding your space’s layout will help you select the most suitable racking system and maximise storage capacity.
Want complete peace of mind in your measurements?
A professional pallet rack installation team will meticulously check all dimensions and positioning, ensuring your pallet racking system is securely and properly installed.
Assess your inventory
Think about the type, size, and weight of the items you’ll be storing. These factors will help determine the racking system you need, including its size and weight capacity.
You should also consider how easily you need to access your inventory, whether you require FIFO (First In, First Out) or LIFO (Last In, First Out) storage methods, as well as how frequently you’ll be retrieving items.
Choose the right warehouse racking
Depending on the available space and storage requirements, select the type of pallet racks that best support your warehouse operations.
Consider factors such as floor capacity, ceiling height, and forklift accessibility when exploring your options.
Moreover, think about future growth to ensure the chosen racking system can support your business as it scales.
You’ll also need to make sure your pallet racking complies with all load-bearing and industry standards.
Given the heavy nature of the racking and the items it will store, weight distribution must be carefully managed on a well-constructed rack that can withstand the required pressure without buckling.
Not sure where to start or can’t find the perfect fit?
At Pallet Racking Sydney, we offer custom pallet rack systems tailored to your warehouse storage needs. Contact us today for a free quote!
How to install pallet racks in 3 steps
The installation process for pallet racks varies based on the type of racking system, so it’s crucial to follow the specific instructions for your setup. Generally, you’ll need at least two people to complete the installation.
The process can be broken down into two main stages: first, constructing the upright frames, and second, assembling the frames and beams to form a bay.
Here’s a general step-by-step process for how to assemble pallet racking:
1. Assemble the upright frames
Pallet rack installation starts with the upright frames.
Each frame has two posts joined together by bracing, and with a footplate at their base.
Here’s how to assemble this component:
- Lay the two posts on the ground, parallel to each other.
- Attach the footplate at the base of each post and secure it with bolts and nuts.
- Fasten the horizontal and diagonal bracing according to the manufacturer’s specific requirements. A common bracing pattern is a “K”.
- Erect the bay by standing the frame upright in position with the footplate on the floor. Known as the impact point, the first diagonal node point should face the aisle.
Make sure these frames are vertical and stable with all components correctly fitted before you continue.
2. Clip in the beams
Install the horizontal beams carefully, making sure they are firmly locked into the upright frames. These beams must be level and spaced appropriately to fit the size of the pallets being stored. The end of every beam should have a safety clip.
Choosing the right gauge and size of beams is crucial for safety and durability, as it helps ensure adequate load support.
Then it’s time to check positioning and secure the racking to the ground.
3. Double check connections
Arrange components thoughtfully and precisely mark the floor for the starter bay to guarantee accurate installation.
After assembling the frames and beams, confirm that all connections are secure and stable. You’ll also need to make sure the bay is in its final position, squared and levelled.
Finally, fix both end frames to the floor with anchors.
How long does it take to install pallet racking?
The time needed to install pallet racking can vary depending on the scale and complexity of your project. A small, simple system might be done in a few days, while bigger, more complicated setups could take several weeks.
Factors like the type of racking, how ready the site is, and the experience of the installation team all play a part in determining the timeline.
Can I install pallet racking myself?
Whether or not you are legally allowed to install pallet racking yourself depends on the state or territory you are in.
For example, in Queensland, these systems must be installed by a professional with a QBCC License.
However, no matter where your warehouse is located, we strongly recommend partnering with a professional team to ensure the pallet racking is installed correctly to AS4084-2023.
That’s because this system must stand the test of time and remain safe, with no risk of collapse from uneven weight distribution or loose fastenings.
When selecting your installation team, make sure they have:
- Comprehensive insurance coverage
- Well-maintained equipment
- Safety harnesses for use at heights
- Rigorous quality assurance checks
- Issuance of a completion certificate
These elements show that you’re working with a skilled team who know how to assemble pallet racking and are committed to making your warehouse both safe and efficient.
If you have any doubts about the team’s ability to safely install your racking, ensure they meet all safety protocols before moving forward.
Reliable pallet racking installation in Sydney
Now that you know how to install pallet racking – and the importance of hiring a professional – you can get started on maximising your warehouse storage.
For dependable support from start to finish, call in the professionals at Pallet Racking Sydney. Our licensed and insured installers have the expertise and equipment to ensure safe, durable and compliant assembly.
We manufacture and install custom pallet racking systems to Australian Standards so that you can optimise storage without sacrificing safety. Contact us today.
*Importantly, this is just a general guide, as every pallet racking system has distinct requirements. Therefore, we strongly recommend seeking professional advice before you begin any installation work.
