A Step-by-Step Guide to Setting Up Pallet Racks in Your Warehouse

Properly installing pallet racks in your warehouse can maximize your storage, improve your workflow, and keep everyone safe.

Once you have your warehouse layout design in place, stamped engineering drawings, and permits, it’s time to get started.

Pre-Planning

The first step is planning before installation. You need to make sure you have the right material handling equipment for your warehouse, the right design and layout, and a trained installation crew. Without these things in place, you can make costly mistakes.

Ensure your installers comply with all OSHA regulations and have the proper personal protective equipment (PPE) to do the job safely.

Take Inventory

Make sure you have the right racks and all their associated parts. You’ll want to put eyes on each component and compare it with your project documents and invoices to make sure you have what you need on hand. If anything’s missing, you need to know before you start and contact the supplier immediately.

It’s a good idea to organize your materials ahead of time so you can quickly locate the pieces you need.

Verify the Layout and Supports

Make sure you get engineering sign-off on flooring and support. For example, a six-inch slab is generally suggested for typical pallet racks in a warehouse, but your needs may vary. Floor slabs must be designed to support fully loaded racks.

With your design plans in hand, you can outline chalk lines on the floor for your layout, double-checking to make sure you have adequate aisle widths and access to the front of rack columns.

Set up the First Pallet Rack in Your Warehouse

Assemble the first rack in place and make sure that it’s level and elevations are correct. Note any discrepancies before you continue, and make sure everything’s right.

That first rack is important. It needs to be plumb down-aisle and cross-aisle. This may require some slight modifications, such as shims, before tightening the bolts and locking mechanisms. Check the manufacturer’s recommendations for proper connections and tightening. For example, some manufacturers have specific requirements for bolt torque in ft-lbs.

Beams must also be level and spaced properly to accommodate the size of the pallets being stored.

Anchor Your Racks

Many projects require specific anchoring to ensure safety and handle weight load properly. Make sure you follow the manufacturer’s instructions here as well. Depending on your setup, you may need different size base plates.

While some building codes allow for anchors to be omitted for smaller or shorter racks in low seismic areas for manual loading, it’s best practice to anchor all pallet racks for warehouse safety.

Starting on the Rest

With the first rack set in place, it’s time to start on the rest of the project, making sure that each additional rack remains plumb in both down-aisle and cross-aisle directions. Be careful when making adjustments. For example, avoid pulling a rack into plumb after you tighten the fasteners as it can cause stress and damage the rack.

As installation continues, continuously check plumb lines with each addition. If one rack gets off kilter, it can throw off your design, which is much harder to fix after the fact.

Add Accessories

Once a rack row is installed, plumbed, and tightened, you need to install back connectors, column protectors, and any cross bars or wire decking. Note that some types of column protectors may require fitting before anchoring or require a common anchor bolt with the rack.

Items like crossbars and wire decking can generally be installed after the rack row frame and beam installation is finished and the racks are anchored. Non-waterfall style racks should be screwed in place so they cannot fall between the beams.

Inspections at Each Stage

Throughout each step of your installation, you need to inspect the racks to ensure the proper procedures have been followed and everything has been done correctly. The sooner you see any issues, the easier they will be to fix.

A detailed checklist can be helpful here so that your inspectors sign off on each aspect of your pallet rack warehouse installation. This provides an audit trail that can be helpful if there are questions about safety compliance.

The checklist should verify critical elements, such as:

  • Proper anchor bolt installation and torque specifications
  • Vertical plumb of uprights
  • Level and square beam connections
  • Secure beam safety locks
  • Correct spacing between racks
  • Installation of all required safety components
  • Conformance to layout specifications
  • Overall structural integrity

Get Expert Guidance on Pallet Rack Warehouse Installation

Conesco Storage Systems can help you with every phase of your installation, including:

Call Conesco Storage Systems at (303) 690-9591 or contact us online to discuss all of your pallet rack and material handling equipment needs.

Request a Consult
Avatar photo

Ted Hodges

Ted Hodges is the Founder and CEO of Conesco Storage Systems, a company he started in 1986 to provide turnkey warehousing products and services, including the repurposing of quality, used material handling equipment. With over 40 employees across the country, Ted and his team serve customers of all sizes throughout the different stages of the warehousing lifecycle. Learn more about Teddy.

“Over the past few years Conesco has proven to be valuable partners for our growing company. They understand their market and the priorities of our business, often helping us stay ahead of changes in demand for new and used racking so that we can get what we want when we want it.  It is good to have a partner that can anticipate your needs and stay ahead of them, that is the level of service that Conesco has demonstrated on a regular basis.”
~ Third Party Logistics [3PL] Company
“Working with Conesco was great. They asked the right questions, understood what we needed and our Denver Facility went in under budget. Good guys, good prices, and good services.”
~ Multinational Grocery Supply Company
“We have worked with Conesco for over 8 years, they are leaders in the Racking Industry, exceptional customer service and great in every aspect to work with. I refer them to anyone I know with racking needs.”
~ Third Party Logistics [3PL] Customer

MATERIAL HANDLING SOLUTIONS EXPERTS

NEW & USED INDUSTRIAL PALLET RACK

“Conesco gave us the top dollar cash offer for our standing pallet rack. They also provided the crew to tear it down and get the material out of our building within the tight time-frame that we had to be out. Their team was very helpful throughout the process. We recommend working with them.

~ National Beverage Distribution Company

Get A Quote

TALK WITH AN EXPERT. CONTACT US.

Conesco can help. Complete our contact form or call us directly at: (303) 690-9591.

“Working with Conesco was great. They asked the right questions, understood what we needed and our Denver Facility went in under budget. Good guys, good prices, and good services.”
~ Multinational Grocery Supply Company
“We have worked with Conesco for over 8 years, they are leaders in the Racking Industry, exceptional customer service and great in every aspect to work with. I refer them to anyone I know with racking needs.”
~ Third Party Logistics [3PL] Customer
“Over the past few years Conesco has proven to be valuable partners for our growing company. They understand their market and the priorities of our business, often helping us stay ahead of changes in demand for new and used racking so that we can get what we want when we want it.  It is good to have a partner that can anticipate your needs and stay ahead of them, that is the level of service that Conesco has demonstrated on a regular basis.”
~ Third Party Logistics [3PL] Company

MORE MATERIAL HANDLING RESOURCES