Proper pallet racking installation is essential in any warehouse, as it directly impacts operational efficiency, safety, and the storage capacity of your facility. A safe and effective racking system allows for optimised storage, easy access to inventory, and, most importantly, protects workers from potential accidents. In this guide, we’ll walk through each step to help you achieve a well-structured and safe pallet racking setup.
Why Proper Pallet Racking Installation Matters
A well-installed racking system doesn’t just maximise storage; it also keeps operations running smoothly and safely. Correct installation reduces the risk of collapses and damage to goods and ensures that inventory handling is efficient. For any warehouse, prioritising safety and efficiency in pallet racking is a sound investment.
Section 1: Preparation Before Installation
Preparation is the foundation of a successful installation. Here’s what to consider:
Conduct a Site Survey and Plan the Space:
Start with a detailed survey of your warehouse space to understand the layout and dimensions. This will help in planning the racking arrangement and avoiding any obstructions, such as columns or HVAC units.
Assess Load Requirements and Select the Right Racking Type:
Understanding what will be stored, and the weight each shelf will bear, is key to selecting the right racking type and configuration. Heavy items may need reinforced racking, while lighter goods may allow for a simpler structure.
Safety Regulations and Compliance Checks:
It’s vital to comply with all local safety standards and regulations. This includes checking for building code requirements related to weight limits, structural support, and emergency exits. Your pallet racking installation will require certification and council consent.
For certification, you will need to work with your racking supplier to obtain a PS1 as a minimum. The PS1 is a producer statement that specifies how the racking should be installed in order to be fit-for-purpose. A registered engineer will review all the factors that influence weight loading capacity such as concrete floor strength, height of the proposed levels, the screw anchors to be used, and the bracing pattern on the pallet racking uprights. The PS1 will dictate what materials you use to install the pallet racking and ensure that it can be certified for the required weight loads when installed. It will also confirm tolerances such as specifying that racking must be installed 300mm clear of any building structural members.
For installations of racking taller than 4m, a PS2 may be requested by Council. A PS2 (Peer Review) involves a second engineer checking the original calculations and confirming that the PS1 is valid. To get the certification documents usually takes only 2-3 weeks.
For the council consent process, you will need to compile a number of reports. This is usually something that your racking supplier can assist with and is something Shelving Depot offers as a service. The Council wants to make sure that installing the pallet racking does not compromise the building from a fire and egress point of view. A fire engineer will need to be engaged to produce an updated fire report that shows the proposed racking layout. These updated reports will be submitted to Council along with the PS1 and PS2 for approval. Often, the Council will require some upgrades to the building fitout such as additional exit signage and emergency lighting but if your building is older, other more onerous upgrades can be required. The process of gathering reports, submitting to Council, and obtaining approval can take 8-12 weeks.
Section 2: Gathering Necessary Equipment and Tools
Having the right tools and safety gear ready will make the process smoother and safer.
Tools and Materials Needed for Assembly:
Common tools include a level, stringline, mallet, concrete drill, measuring tape, and driver. Ensure you have all required racking components on hand, such as uprights, beams, braces, and anchors. For pallet racking frames taller than 2.4m, height access equipment and a forklift will be required.
Ensure Availability of Safety Equipment:
Equip your team with helmets, gloves, safety glasses, and steel-toed boots. Adequate PPE (personal protective equipment) is essential for preventing injuries during the installation process.
Section 3: Step-by-Step Installation Process
Once prepared, follow these steps to install the racking correctly:
Layout and Mark Positions on the Floor:
Lay out the racking system according to your space plan. Use chalk or tape to mark where each upright will go. Use a string-line to ensure that rows are straight and aisles are an equal width for the whole length.
Installing Each Line:
The setup of the first pallet racking bay in each line is critical. One common mistake is that the first bay is not installed square. This will not impact whether the line of racking is straight but will impact the final bay. When you have stood the first pallet racking bay, measure the distance from one corner to the opposite corner. Then compare the measurement of the alternative. Both measurements in this ‘X’ will be the same if the unit is square. Once this bay is square, use a minimum of one anchor bolt per foot to pin the bay in place before you proceed with installing the remainder of the racking.
Use pallet racking shims to ensure the pallet racking is level. Often, warehouse floors are not level so shims should be used to ensure that the racking uprights are level. This can mean that one baseplate is propped up while the other sits directly on the concrete. If you don’t install the racking level, the weight distribution will be uneven which can impact the structure.
Once the first bay is installed and pinned in place, continue with the remainder of the line. As you install the horizontal beams, ensure that the safety-clips are engaged before you install the next beam. Dis-engaged beams can become dislodged creating a serious risk for installers.
Alignment and Bolt Down
When the full run of racking is complete, double-check that it is aligned and straight before securing all the frames to the ground with anchor bolts. Check the PS1 document to make sure you are using the correct anchor bolts and bolting pattern.
Secure Bracing and Confirm Structural Integrity:
When installation is complete, do one final check to ensure that all beam clips are engaged and all anchor bolts are tight.
Section 4: Safety Considerations During Installation
Safety should be a priority throughout the setup process.
Create Exclusion Zones for Duration of Installation:
It is recommended to create an exclusion zone around the area installation is taking place. This is best achieved by using cones and basic signage to ensure that any pedestrians or staff members not involved in the installation stay clear of the work zone. During the installation, forklifts and scissor lifts will be regularly moving about so it is critical that no unauthorised access is permitted.
Enforce the Use of PPE and Follow Safety Protocols:
Ensure everyone involved is equipped with PPE and follows safety protocols, such as lifting techniques and awareness of surroundings. Make sure that equipment operators are trained and qualified, particularly on forklift and height access equipment.
Regular Inspections During Setup:
Frequent checks help catch issues early on. Inspect alignment, load distribution, and fastening integrity as you progress with the installation.
Section 5: Post-Installation Checks and Maintenance
Once the racking is assembled, thorough checks will ensure it’s ready for use.
Verify Structural Integrity and Alignment:
Go over the entire system, checking that all components are securely fastened and aligned. Adjustments may be needed if there’s any wobbling or misalignment. You will need to install weight loading signage that aligns with the PS1 document. This will need to be installed strategically so that anyone putting away stock can easily identify the weight loading capacity. The most common practice is to install the weight loading signage on the end of each aisle. This means that as drivers move pallets into the aisle they are able to check the weight loading limitations and ensure they comply.
Conduct Compliance Checks:
To complete the certification process on your pallet racking, you will need to obtain a PS4. The engineer that provided the PS1 (Engineered Design) will be involved in providing the PS4 (Construction Review). At this point, the engineer will inspect the installation to check that it has been installed as specified in the PS1. When confirmed, the engineer will issue the PS4 to certify that the pallet racking is fit for use as per the weight loads agreed on. Some things that the engineers will look out for include weight loading signage, correct screw anchor connections, beam connections, and bracing configurations.
A final inspection is also required for the Council Consent process to obtain a Code Compliance Certificate (CCC). It is important to fulfil the whole scope of the consent prior to inspection otherwise they will not provide the CCC. You will need to check the conditions of the consent to make sure you have the appropriate signage, have made the correct changes to the emergency lighting etc.
Implement Routine Maintenance for Longevity:
Regular maintenance is key to extending the racking system’s lifespan. Inspect bolts, beams, and braces regularly and replace any damaged parts promptly. We recommend that an annual audit is completed by an external provider and that monthly checks are completed by your team.
Section 6: Expert Tips for a Smooth Installation
These tips from experienced installers can help make the process quicker and safer:
Time-Saving Tips from the Pros:
Consider pre-assembling some components before installation day to save time. Additionally, using laser levels or chalk lines ensures straight rows without constant re-measuring.
Ensure the plan is confirmed prior to installation. Last minute changes are one of the biggest time-wasters during installations. Investing the time prior to installation to confirm beam level spacings and configuration will reap benefits when you are installing. 5mins of extra planning can save hours of rework onsite.
Spread the unassembled items out based on location. For example, if you have a medium size warehouse, you could put half the components in the middle and the other half nearby the location you intend to put your last run of racking. This will stop you from moving all the stock as you work through the installation.
Training Warehouse Staff in Racking Use and Safety:
After installation, training staff on how to safely load, unload, and inspect the racking will reduce wear and tear, prevent overloading, and extend the system’s lifespan.
Proper preparation, installation, and maintenance are the cornerstones of a safe, efficient pallet racking system. By following this step-by-step guide and keeping safety top of mind, you’ll create a racking setup that maximises storage and minimises risk. And remember, for complex or large installations, consulting a professional installer can ensure the job is done right from start to finish.
