Planning pallet racking: what to check for load, beam pitch and safety?
Pallet racking stores palletised goods on beam levels served by forklifts. The key figures are beam load per level and bay load, upright height and depth for the pallet type, adjustable beam pitch, aisle width for the truck, plus rack protectors and inspection to EN 15635.
View storage technologyHow does pallet racking work and how does it differ from shelving?
Pallet racking carries palletised goods on horizontal beams hooked between upright frames. Each level typically holds two or three pallets that a forklift places directly. Unlike shelving for small parts, it is built for heavy unit loads, forklift access and flexible level heights.
The basic unit is the rack bay: two upright frames plus the pairs of beams between them. By hooking and repositioning the beams in the perforated grid, the beam levels can be matched to different pallet heights without rebuilding the rack.
Which key figures define load capacity and dimensions?
The decisive values are beam load per level and bay load per rack bay, the upright height and depth to suit the pallet type, the beam pitch grid, and the aisle width for the truck in use. The manufacturer sets these figures and they must not be exceeded in operation.
- Always read beam load per level and check bay load as the sum of the loaded levels.
- Choose the upright depth so the pallet rests securely on both beams.
- Beam pitch = pallet height plus load plus clearance for placing and retrieval.
- Size the aisle width to the specific forklift type and turning radius.
How do you plan pallet racking safely and to standard?
Safety comes from correct loading, rack protectors and regular inspection. Rack protectors on uprights and corner posts absorb forklift impacts, clearly visible load signs state the permitted beam and bay load, and the rack inspection per EN 15635 documents the condition.
Guards on aisle-side uprights and corner posts prevent forklift damage.
View accessoriesFrequently asked questions
What is the difference between beam load and bay load?
The beam load is the permitted capacity of a single beam level. The bay load is the sum of all levels in one rack bay between two upright frames. The manufacturer sets both limits and neither may be exceeded.
How high should a level in pallet racking be?
The beam pitch follows from the height of the pallet plus its load plus clearance for safe placing and retrieval. Because the beams are adjustable in the perforated grid - usually 50 to 75 mm - each level can be matched to the pallet height.
How often must pallet racking be inspected?
Under EN 15635 ongoing visual checks and a documented expert inspection at regular intervals are required. Damaged components must be assessed and, where needed, unloaded or replaced.
Configure pallet racking correctly
Our storage specialists help with load capacity, beam pitch and standard-compliant safety.
Clear load ratings
Beam and bay load as the leading planning figures.
Right dimensions
Upright depth and beam pitch to the pallet type.
Safety
Rack protectors and load signs planned in.
EN 15635
Inspection concept for ongoing operation.