When it comes to planning and manufacturing, most pallet racking systems are designed and installed specifically for your needs and the environment you’re working in. Components and capacity can vary significantly and can depend on a lot of factors, from what you’re stocking on them to how deep the beam is. That’s precisely why Racking + Shelving Ltd. designs, manufactures and install custom pallet racking for our clients across Northern Ireland and the UK.

But to maintain a safe working environment and avoid overstacking, it’s useful to know the weight limits of your pallet racking. Here’s a brief guide to understanding pallet racking weight limits for those who already use or are planning to use pallet racks in a warehouse.

Basic pallet racking information

There are 3 main types of pallet racking: standard adjustable pallet racking, narrow aisle racking and drive-in racking.

In the UK, the size of the pallet is usually 1200mm x 1000mm. But in the EU, pallet sizes are typically 1200mm x 800mm.

For safety and convenience, it’s recommended that each rack is fitted with a load notice that clearly indicates the maximum loading of your racking.

Pallet racking weight limit considerations

When we design your custom pallet racking system, or you need to work out your maximum weight load, there are several factors that must be considered:

• Bay clear entry width: The distance in millimetres between the insides of each vertical beam. Remember that this measurement is for width, not depth. So it must be measured from the front face of your pallet racking system.
• Beam depth: This is measured across the top of the beam. Most pallet racking systems have a beam depth of 40mm or 50mm. But in some cases this can be different.
• Beam face depth: Not to be confused with beam depth, which is fairly standardised. In contrast, beam face depth can vary significantly, from 80mm or 90mm all the way up to 150mm. The deeper the beam, the greater the maximum weight limit for pallet racking.
• Racking beam section: Racking beams come in two types, both with different maximum load capacities. Box beams are fully enclosed and are manufactured from C-sections, making them suitable for heavier loads. Open beams, on the other hand, are made from a single formed steel section and are commonly used to hold lighter weights.
• Racking frame size: This is the measurement of the height (H) x width (W) of your frame, taken in millimetres. In this case, width refers to the front-to-back dimension of your pallet racking system.
• Vertical beam pitch: This refers to the height of each storage level on your pallet racking system, measured from the floor to the top side of each beam. This affects the intervals at which beams can be placed. If the number of beam levels is different across your pallet storage system, your pallet racking weight limits will be different as well.
• Upright duty: Pallet racking systems are typically stamped with one of 3 letters to denote their strength: H for heavy duty, M for medium duty or S for standard duty. These different upright duties are designed to hold different weights. So it’s important to know your system’s upright duty to calculate your maximum pallet racking weight limit.

Maximum load for pallet racking

In general, the maximum load allowed per pair of beams is normally 4 tonnes. But it can vary depending on your duty frames:

• Standard-duty frames can normally carry nine tonnes
• Medium-duty frames can usually hold 15 tonnes
• Heavy-duty frames have a maximum load of 20 tonnes

These are general weight limits but it will all be dependent on the heights and depths of the frame itself and the design process.

How do I calculate pallet racking weight limit?

Use this simple formula to work out how much weight your pallet racking can take:

Maximum load per pair of beam ×Frame load =Pallet racking capacity

And use this one to figure out your total number of layers:

Frame load/Maximum load per pair of beams =Total number of layers

What happens if I exceed the pallet racking weight limit?

Knowing and sticking to your pallet racking weight limit is vital to keeping your warehouse safe.

Remember that it’s the warehouse owner’s responsibility to ensure the safety of staff. This includes proper training on the pallet racking weight limits to avoid unsafe pallet racking.

If the load on your pallet racking system exceeds its limit, there’s a serious risk that it could collapse. Such an incident could lead to:

• Injury of staff and visitors, and the potential for lawsuits
• Expensive repairs that could have been easily prevented
• Fines for failing to comply with industry safety standards
• Extended downtime as you replace equipment and stock

Get custom pallet racking systems for any weight

As Northern Ireland’s storage specialists, Racking + Shelving Ltd. designs, supplies and installs high-quality bespoke storage solutions, including pallet racking. Whatever you’re looking to store in your warehouse, our expert team can design pallet racking systems specific to your weight and needs. Contact our friendly team today.