Pallet Racking: 11 Popular Types and Installation Pricing

Warehouse racking is an essential storage solution that helps optimize space and enhance inventory management efficiency in warehouses, factories, and logistics centers. Manufactured from high-tensile steel, warehouse racking is primarily classified based on load capacity and design, ranging from traditional racking to smart, automation-integrated racking systems.

4 Popular Types of Smart Warehouse Racking Today

Popular smart warehouse racking systems include Radio Shuttle racking (automated robotics), AS/RS systems (automated storage and retrieval), Mobile Racking, and Hand-Cranked racking. These solutions help optimize up to 90% of warehouse space, increase loading and unloading speeds, and significantly reduce labor costs.

Radio Shuttle Racking

Radio Shuttle racking is a modern automated racking system that utilizes a robotic shuttle running on rails within the racking lanes to move pallets automatically. Controlled via remote or warehouse software, it accelerates the loading and unloading process, minimizes collisions, and is highly suitable for high-density storage, particularly in cold or freezer storage environments.

• Load Capacity: 500 – 1500 kg/pallet (can be customized up to 2000 kg depending on design).
• Height: Up to 11 – 12 m (maximizing warehouse vertical space).
• Storage Density: 70% – 85%.
• Input/Output Method: Automated via robotic shuttle (Flexible FIFO/LIFO); forklifts only drop off or retrieve pallets at the rack face.

AS/RS System

AS/RS (Automated Storage and Retrieval System) is a fully automated smart warehouse solution designed to execute the entire storage and retrieval process automatically. The system utilizes automated stacker cranes, robots, conveyors, shuttles, and warehouse management/control software (WMS/WCS) to input, store, retrieve, and transport goods to required locations with little to no human or forklift intervention.

• Load Capacity: 1500 kg/pallet (varies based on unit load or mini-load configurations).
• Height: Up to 40 – 45 m (optimizing maximum warehouse height).
• Storage Density: 90%.
• Input/Output Method: Fully automated via cranes/robots and conveyors (Software-controlled FIFO/FEFO; requires no human entry into the racking area).

Mobile Racking

Mobile racking is a pallet racking system mounted on mobile bases that travel along floor rails, opening an access aisle only when required (the racks compact tightly together when not in use). Powered by electric motors or hand cranks, this system can save up to 80% of floor space.

• Load Capacity: 800 – 1500 kg/pallet (depending on design; suitable for medium to heavy loads).
• Height: 2 – 12 m (depending on warehouse height).
• Storage Density: 80% – 90%.
• Input/Output Method: Standard forklifts (100% accessibility when the aisle is opened); motor-controlled racking movement.

Mobile Shelving

Mobile Shelving is a compact storage system that uses a mechanical hand crank to move the racks and open an aisle. It is ideal for archiving documents, small components, or lightweight goods, providing high-density storage at a much lower cost than motorized systems.

• Load Capacity: 100 – 500 kg/level (not suitable for heavy industrial loads).
• Height: 2 – 8 m (suitable for small to medium-sized warehouses).
• Storage Density: 75% – 85%.
• Input/Output Method: Light material handling equipment or manual picking (direct access when manually cranked open); simple manual operation.

7 Popular Types of Heavy-Duty Industrial Racking

Common heavy-duty industrial racking systems include Selective, Double Deep, Drive-In, Flow, Mezzanine, Push Back, and VNA racking. They are classified based on load capacity and operational methods, helping to optimize storage space and goods throughput speed.

Selective Racking

Selective racking is currently the most widely used warehouse racking system, allowing 100% direct access to each individual pallet. The system is designed with dedicated aisles between rack rows, enabling forklifts to easily store and retrieve any pallet without having to move others.

• Load Capacity: 500 – 3000 kg/pallet (typically 1000–2000 kg).
• Height: Up to 15 m.
• Storage Density: 30% – 45%.
• Input/Output Method: Standard forklifts (Flexible FIFO/LIFO).

Double Deep Racking

Double Deep racking is an industrial storage system created by placing two rows of Selective racking back-to-back, forming a two-pallet deep storage location. This design significantly increases storage density compared to standard Selective racking while reducing the number of forklift aisles, thereby optimizing warehouse floor space.

This is an ideal storage solution for warehouses that need to store a large volume of pallets but have limited floor space. Double Deep racking can increase warehouse capacity by 30%–50% compared to a Selective system while maintaining effective inventory management when combined with specialized reach trucks.

• Load Capacity: 3000 kg/pallet.
• Height: Up to 10 m.
• Storage Density: 40% – 65%.
• Input/Output Method: Reach trucks (LIFO, 50% accessibility).

Drive-In Racking

Drive-In racking is a high-density warehouse racking system that stores goods using the LIFO (Last-In, First-Out) method. This system optimizes storage space by eliminating most aisles between rack rows, allowing forklifts to drive directly into the storage lanes to load and retrieve pallets.

Thanks to this design, Drive-In racking significantly increases warehouse capacity compared to traditional systems, maximizing both floor space and vertical height. It is a suitable solution for businesses storing large quantities of homogeneous pallets where FIFO dispatch is not strictly required.

• Load Capacity: 1000 – 2000 kg/pallet.
• Height: Up to 12 m.
• Storage Density: 65% – 80%.
• Input/Output Method: Forklifts driving into internal lanes (LIFO).

Pallet Flow Racking (Flow Rack)

Pallet Flow Racking (Flow Rack) is a semi-automated storage system that manages goods using the FIFO (First-In, First-Out) method. This system utilizes roller tracks installed on a slight decline, harnessing gravity so that pallets or cartons automatically glide from the loading face to the retrieval face.

• Load Capacity: 1000 kg/pallet.
• Height: Up to 10 m.
• Storage Density: 60% – 75%.
• Input/Output Method: Forklifts load pallets at the higher end and retrieve them at the lower end (Automated FIFO).

Mezzanine Floor Racking

Mezzanine Floor racking creates a raised storage platform using a heavy-duty steel framework, utilizing warehouse height to increase usable space by 2 to 3 times. The ground level typically stores heavy pallets, while the upper level(s) are used for lightweight goods, offices, or packing areas.

• Load Capacity: 500 kg/m² of floor space (depending on the tier).
• Height: Maximum total height of 8 m.
• Storage Density: 400% of the warehouse footprint.
• Input/Output Method: Forklifts/goods lifts for upper levels, combined with Selective or medium-duty shelving.

Push Back Racking

Push Back racking is a semi-automated warehouse storage system utilizing the LIFO (Last-In, First-Out) method. The system allows pallets to automatically roll forward to the picking position via gravity, utilizing a series of nested carts mounted on inclined rails.

When a new pallet is loaded, it pushes the existing pallets deeper into the rack lane. Conversely, when the front pallet is retrieved, the remaining pallets automatically glide forward, making the loading and unloading process fast and efficient.

• Load Capacity: 500 – 2000 kg/pallet.
• Height: Up to 9 m.
• Storage Density: 60% – 75%.
• Input/Output Method: Forklifts push pallets into the lane (LIFO; pallets slide forward automatically upon retrieval).

VNA (Very Narrow Aisle) Racking

VNA (Very Narrow Aisle) racking is a heavy-duty pallet racking system designed with aisle widths of only 1.5 – 2.2 m. By using specialized VNA forklifts (turret trucks) that operate within these narrow aisles, this system maximizes storage area while ensuring direct access to every single pallet.

• Load Capacity: 3000 kg/pallet.
• Height: Up to 15 – 17 m.
• Storage Density: 55% – 70%.
• Input/Output Method: FIFO/LIFO.