Pallet Rack Design Form

Pallet rack design can be a complicated process. It’s important to figure out the needs and physical limitations of your business before investing in a pallet rack system. The following information outlines the information needed for purchasing the proper racking. By printing this article and filling in the blanks, you will be prepared to answer the questions you will be asked when ordering your custom pallet rack system. To purchase a pallet rack system visit www.materialflow.com or call 1-800-338-1382.

Step 1. Length of Beam
Select which type of lift truck you will be using.
Counter Balanced Truck
Straddle or Outrigger
For Counter Balanced

Maximum width of pallet or load (whichever is larger) __________

Number of loads across (between upright frames)_______________

Allow 3″ between upright frame and loads.

Allow 4″ between loads

Example: Allow 10″ for two across storage.

Total length of beams (Max load width plus allowance)

The clear distance between posts will be beam lengths plus space between plate and columns.

For Outrigger or Straddle

Inside Clearance between outriggers ____________X 2=_____________

Width of outriggers plus 3″__________ x 3=__________________

*Total Beam length ___________

*If load overhangs outriggers, add amount of overhang for each load.


Load Types
This diagram shows the difference between wing and flush pallets.
A) Depth of pallet or load
B)Width
C) Height
D) Total Height (load and pallet)
E) String Dimension
F) Total Weight (load plus pallet)
Step 2. Beam Capacity

Number of pallets____ X load weight = required capacity per pair____Beam capacity ___ lbs. for ___length = type____________

The beam capacity chart represents the uniform distributed load to be carried by a pair of beams. For single level racks, decrease beam capacity by 15% to account for the reduced end fixity, and use only heavier beams, which have four hook end connectors.
Step 3. Frame Depth and Spacers
Frame depth A). should be 6″ less than pallet stringer dimension________________ (must be in 3″ increments)Row Spacers and Wall Fixes
Suggested row spacer length:Amount of pallet or load overhang___________ x 2 ___________

Add 6″ (suggested clearance)=_____row spacer length

Wall fix: pallet or load overhang:___________ + 6″__________ wall fix length__________


Pallet Guide
A: Depth (Stringer Length)
B: Width (Board Length)
C: Height

For more information on Pallet Rack systems visit www.materialflow.com or call 1-800-338-1382

Step 4. Frame Upright Height
Starting at floor level:Add height of pallet and load (A)_________ (B) and (C) or use 9″Add clearance between top of load and bottom of beam (B)____________

Add thickness of support beam

Total_______________________

Multiply total times the number of shelf levels

_________ to equal frame height

Rack is required to go only as high as is necessary to support top pallets. Height may also be limited by the extent of fork elevation of lift truck. Provide a minimum of 6″between top load and ceiling obstructions. (Check local fire codes)
Step 5. Frame Capacity
Add total of loads supported by shelf beams___________Determine maximum vertical shelf spacing (x)__________________Determine number of levels per bay___

and bays per row___________

For great deals on pallet rack systems visit www.materialflow.com or call 1-800-338-1382