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The Complete Pallet Rack Guide: SYSTEMS, Types, and Measurement Standards
Choosing the right warehouse storage solution is critical for maximizing floor space and streamlining inventory management. Because no two warehouses are the same, selecting the right pallet rack system—and measuring it accurately—is the key to a safe and efficient operation.
Whether you are looking to maximize storage density, maintain 100% SKU accessibility, or need to measure your current system for expansion, this guide covers everything from common racking types to essential hardware measurements.
find the right system
Most Common Types of Pallet Rack Systems
Selective Pallet Rack
BEST FOR:
Versatility and 100% SKU accessibility.
Overview:
The industry standard. Selective racks offer direct access to every pallet. They are easy to install, highly customizable, and ideal for warehouses with high SKU counts and fast-moving inventory.
Double Deep Rack
BEST FOR:
Increasing storage density without expanding your footprint.
Overview:
By placing one row of pallets behind another, you increase density by 40%. It requires a deep-reach forklift and is best for slower-moving inventory since it reduces immediate access to the rear pallet.
Drive-In / Drive-Through Rack
BEST FOR:
High-density storage of uniform products.
Overview:
Forklifts drive directly into the rack lanes. Drive-In utilizes one entry/exit point (LIFO), while Drive-Through allows access from both ends (FIFO).
Narrow Aisle Rack (VNA)
BEST FOR:
Maximizing capacity in tight spaces.
Overview:
Used with specialized Very Narrow Aisle (VNA) forklifts, these systems reduce aisle widths to significantly increase storage capacity while maintaining direct access to all pallets.
Push Back Rack
BEST FOR:
High-selectivity LIFO operations.
Overview:
Pallets sit on nested carts that glide on inclined rails. When a new pallet is loaded, it "pushes back" the others. It’s an excellent high-density solution for multiple pallets of the same SKU.
Pallet Flow (Gravity Flow)
BEST FOR:
High-volume FIFO (First-In, First-Out) rotation.
Overview:
Pallets are loaded from the back and glide on rollers toward the front. This is the gold standard for perishable goods and high-turnover distribution centers.
Pallet Runner / Radio Shuttle
BEST FOR:
Semi-automated, high-density storage.
Overview:
A remote-controlled cart moves pallets within deep lanes, reducing forklift travel time and increasing throughput.
Cantilever Rack
BEST FOR:
Oversized, long, or bulky items.
Overview:
Featuring arms instead of traditional shelves, these are designed for lumber, pipes, and furniture. They offer unobstructed horizontal space for non-palletized goods.
AS/RS (Automated Storage & Retrieval System)
BEST FOR:
Large-scale, high-speed automated warehouses.
Overview:
uses computer-controlled robotics to handle pallets with extreme precision and speed, making it the most efficient (though most expensive) solution.
Pallet Rack SYSTEMS Comparison Chart
Use this table to quickly identify which system aligns with your warehouse goals.
Rack Type | Inventory Flow | Best For | Storage Density | Selectivity |
|---|---|---|---|---|
Selective | FIFO/LIFO | Maximum Accessibility | Low | 100% |
Double Deep | LIFO | Expanding Capacity | Medium-High | 50% |
Drive-In | LIFO | Bulk Uniform Products | High | Low |
Push Back | LIFO | Medium-Turn Items | High | Medium |
Pallet Flow | FIFO | Perishables/High Turn | High | Medium |
Cantilever | N/A | Lumber, Pipes, Bulky Goods | N/A | High |
Narrow Aisle | FIFO/LIFO | Space Optimization | High | 100% |
AS/RS | FIFO/LIFO | Large Scale Automation | Very High | 100% |
Rack Type | Inventory Flow | Best For | Storage Density | Selectivity |
|---|---|---|---|---|
Selective | FIFO/LIFO | Maximum Accessibility | Low | 100% |
Double Deep | LIFO | Expanding Capacity | Medium-High | 50% |
Drive-In | LIFO | Bulk Uniform Products | High | Low |
Push Back | LIFO | Medium-Turn Items | High | Medium |
Pallet Flow | FIFO | Perishables/High Turn | High | Medium |
Cantilever | N/A | Lumber, Pipes, Bulky Goods | N/A | High |
Narrow Aisle | FIFO/LIFO | Space Optimization | High | 100% |
AS/RS | FIFO/LIFO | Large Scale Automation | Very High | 100% |
features • compatibility
Pallet Rack Styles
While most pallet rack systems perform the same function, the style refers to the shape of the upright holes and how beams connect. The main difference between styles usually comes down to the manufacturer, not strength or function. However, compatibility matters, especially when expanding an existing system.
Even when styles look similar, they don’t always work together. Here’s a breakdown of the most common ones:
New Style Teardrop
FEATURES:
Rounded teardrop-shaped holes.
KNOWN FOR:
Most common modern rack style.
COMPATIBILITY:
Compatible with most teardrop brands and with Old Style Teardrop uprights/beams.
Old Style Teardrop
FEATURES:
Sharper, more angular teardrop openings.
KNOWN FOR:
Legacy style still widely found.
COMPATIBILITY:
Compatible with New Style Teardrop Beams, but not Uprights. Will go into New Style Teardrop uprights, but not the other way around.
Keystone
FEATURES:
Keyhole-shaped punches on the uprights.
KNOWN FOR:
Strong connection, reliable performance.
COMPATIBILITY:
Not compatible with teardrop or other major styles.
Structural Rack
FEATURES:
Bolted C-Channel steel construction (not roll-formed).
KNOWN FOR:
Heavy-duty strength and impact resistance.
COMPATIBILITY:
Not interchangeable with clip-in styles; used in high-impact or seismic areas.
Penco
FEATURES:
Rectangular holes with tabs.
KNOWN FOR:
Fast, simple installation.
COMPATIBILITY:
Unique to Penco; not cross-compatible with teardrop or other brands.
Ridg-U-Rak
FEATURES:
Custom tab-and-slot pattern, often teardrop-inspired.
KNOWN FOR:
Precision manufacturing and strength.
COMPATIBILITY:
Typically only compatible within Ridg-U-Rak brand systems.
T-Bolt
FEATURES:
Bolt-through beam connection—no clips.
KNOWN FOR:
High capacity and rigidity.
COMPATIBILITY:
Proprietary system; not compatible with clip-in styles.
Speedrack
FEATURES:
Inverted triangle slots for beam clips.
KNOWN FOR:
Clean, secure connections.
COMPATIBILITY:
Only compatible with Speedrack systems.
UPRIGHTS • FRAMES • CLEARANCES
How to Measure Your Pallet Rack System
Understanding Pallet Rack Dimensions & Clearances
When designing your layout, you must account for both the physical size of the rack components and the space required for the pallets themselves.
Upright Frame Dimensions
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Column Height: Measure from the floor to the very top of the vertical upright column.
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Frame Depth: Measure the overall distance from the front of the front column to the back of the rear column.
Beam & Pallet Spacing (Clear Span)
The Shelf Beam Clear Span is the horizontal distance between the two uprights. To determine the correct beam length, you must account for:
-
Side Clearance (5" Min): Maintain at least 5" of space between the pallet and the upright column on both ends.
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Internal Spacing (6" Min): When placing two pallets on a single beam level, ensure there is at least 6" of space between the pallets.
Vertical & Depth Clearances
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Lift Clearance (4" Min): Always allow for at least 4" of vertical space between the top of your load and the bottom of the beam above it to allow for safe lifting and maneuvering.
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Pallet Overhang (3"): For standard safety, pallets should overhang the front and back beams by 3" to ensure the pallet is seated securely on both beams.
Note: Always measure to the nearest 1/16th of an inch. If your measurements don't match standard industry sizes, you may have a specialized or discontinued racking brand.
How to Measure Baseplates and Upright Columns
When ordering replacement uprights or floor anchors, you need to know the exact dimensions of the column and the baseplate that supports it.
Measuring the Baseplate
The baseplate (or footplate) is the steel plate welded to the bottom of the upright.
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Length & Width: Measure the overall outer dimensions of the plate (e.g., a standard size is often 5" x 7" or 8" x 8").
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Thickness: Measure the vertical thickness of the steel plate itself.
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Anchor Hole Spacing: Measure the distance between the center of the pre-drilled holes to ensure they match your existing floor anchor patterns.
Measuring the Column Profile
The "Profile" refers to the shape and size of the vertical steel post.
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Face Width: Measure the width of the front of the column (the side with the teardrop or keyhole punches). Common sizes include 3" or 4".
-
Column Depth: Measure the side of the column, from the front face to the back.
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Steel Gauge: While difficult to measure with a tape, noting the thickness of the column steel helps determine the rack's weight capacity.
Identifying the Punch Pattern
While you have the tape measure out, take note of the Punch Spacing:
-
Measure from the center of one hole to the center of the hole directly above it.
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Standard industrial racking typically uses 2" centers, but some older or specialized brands use 3" or 4" spacing.
Safety Tip: If you notice a baseplate is bent, cracked, or has missing anchors, the upright should be unloaded and replaced immediately to prevent structural failure.
How to Measure Your Pallet Rack Beams
Accurate measurements ensure your new components fit perfectly and maintain the structural integrity of your system. Use the guide below to measure your horizontal beams.
Beam Length (Clear Span)
The most common measurement needed is the Beam Length.
-
How to measure: Measure the distance between the inside faces of the two vertical uprights.
-
Pro Tip: Do not include the thickness of the uprights or the beam connectors in this measurement. Standard lengths are typically 48", 96", 108", or 144".
Beam Face Height
The vertical "face" of the beam determines its weight capacity.
-
How to measure: Measure the flat, vertical front surface of the beam from top to bottom.
-
Why it matters: Even if two beams are the same length, a 6" face height can support significantly more weight than a 4" face height. Ensure you match your existing beams to maintain uniform load capacities across your bay.
Beam Step and Depth
If you are ordering wire decking or cross-bars, you’ll need to measure the Step.
-
How to measure: Measure the inset "ledge" on the inside of the beam where the decking sits.
-
Common Size: Most standard "Step Beams" have a 1-5/8" step.
Note: Always measure to the nearest 1/16th of an inch. If your measurements don't match standard industry sizes, you may have a specialized or discontinued racking brand.
How to Measure for Wire Decking
To ensure a safe and proper fit, wire decking measurements must match both your frame depth and your beam length.
Determining Decking Depth
The depth of your wire decking must match the Frame Depth of your uprights.
-
How to measure: Measure from the outside edge of the front load beam to the outside edge of the rear load beam.
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Standard Sizes: Most common depths are 36", 42", and 48".
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The "Waterfall" Fit: As shown in the image, the wire mesh typically "waterfalls" over the edge of the beam for added security.
Measuring for Decking Width
The width of the decking panels depends on your Beam Clear Span.
-
How to measure: Measure the horizontal distance between your two upright columns.
-
Calculating Panel Count: Most beams require multiple panels. For example, a standard 96" beam usually utilizes two 46" wide panels to allow for a small gap between them and the uprights.
Support Channel Placement
The orange arrows in the lower half of the image highlight the Support Channels (also known as "stays").
-
Function: These channels rest on the beam steps to provide the primary weight-bearing capacity for the deck.
-
What to check: Ensure the depth of the support channel matches the depth of your frame so it seats properly on both the front and back beam steps.
FREQUENTLY ASKED QUESTIONS
GOT PALLET RACK QUESTIONS? WE'VE GOT THE ANSWERS
Browse our Frequently Asked Quetions (FAQ) below or head over to our RESOURCES page to answer any questions you might have about Pallet Rack Systems, Types, Connections, or How to Measure.
QUESTION:
What is the most common upright depth?
ANSWER:
The most common depth is 42”, ideal for standard pallets to ensure weight is supported by the crossbeams, preventing pallet breakage.
QUESTION:
How can I determine what height upright I need?
ANSWER:
Consider your building's clear height and your forklift’s maximum lift height; choose a height close to your forklift's limit that your ceiling can tolerate.
QUESTION:
Should I be using 96” beams?
ANSWER:
Racking should be built to your specific needs; while 96” is common, other lengths may be better depending on your specific application.
QUESTION:
How long will it take to fill my order?
ANSWER:
Fulfillment depends on stock; same-day is possible for in-stock items, while custom builds generally require three to five days.
QUESTION:
What is selective pallet racking?
ANSWER:
A design that allows all bays to be immediately accessible to forklift operators, ideal for warehouses storing many different SKUs.
QUESTION:
What is adjustable pallet racking?
ANSWER:
Most modern systems (Teardrop, Keystone, T-Bolt, Structural) are adjustable, allowing you to change shelf levels as your storage needs evolve.
QUESTION:
What is cantilever pallet racking?
ANSWER:
A heavy-duty system made from I-beam steel designed specifically for long materials like lumber, steel tubing, or conduit.
QUESTION:
Do you carry double deep racking?
ANSWER:
Yes; this system places two rows together to increase storage density, making it great for bulk storage of the same item.
QUESTION:
Does pallet racking need to be certified or permitted?
ANSWER:
This depends on your local municipality or county; you should check local regulations, but we can facilitate certification services if needed.
QUESTION:
Does pallet racking need to be bolted to the floor?
ANSWER:
We always recommend anchoring, especially in areas with forklifts. Some exceptions exist for racks under 10' or without forklift use.
QUESTION:
How much weight can pallet racking hold?
ANSWER:
While customizable for any weight, the average system is designed to comfortably hold 5,000 lbs per shelf.
QUESTION:
How often should I inspect my pallet rack?
ANSWER:
You should perform monthly in-house visual checks and an annual professional inspection to identify column damage or loose anchors.
QUESTION:
What is the difference between roll-formed and structural rack?
ANSWER:
Roll-formed uses clips for easy adjustment; structural rack uses hot-rolled steel and bolts for maximum impact resistance.
QUESTION:
Do I need wire decking?
ANSWER:
While often optional, wire decking is a safety standard that prevents falling items and is frequently required for fire code compliance.
WE BUY PALLET RACK!
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If you have used pallet racking or equipment looking for a new home,
give us a call at 770-414-8700 or use our Contact Us form!
Pallet Rack Supply offers liquidations services for large amounts of used racking and industrial supplies. We complete full-scale decommission projects nationwide, including breakdown and removal of all racking and equipment