Pallet racking is built to last for decades, but the warehouse around it rarely stays the same for that long. Stock profiles change, forklift fleets are replaced, throughput increases and safety expectations rise. A racking system that was right ten years ago can end up holding back the operation or exposing staff to avoidable risks.
The good news is that you do not always need to replace your racking to bring it up to standard. In many cases the right upgrades can make an existing system safer, increase capacity and improve picking efficiency for a fraction of the cost of starting again.
Logical Storage Solutions installs pallet racking in warehouses right across the UK.
Our team can offer you personalised advice when you get in touch. For now, we've put together this explanation about how to upgrade pallet racking systems and covers the features that make the biggest difference.
Start with an assessment
Every upgrade should begin with an understanding of what you already have. Before adding components or changing the layout, you need to know:
- The manufacturer and type of racking installed, as components from different systems are not always compatible
- The current load capacity of each bay and beam level
- The condition of uprights, beams and fixings, including any existing damage
- How the racking is being used day to day, including pallet sizes, weights and handling equipment
A professional pallet racking inspection is the best starting point. It will identify damage that needs repairing before any upgrade work begins and give you an accurate picture of the system’s condition. If you are not yet sure whether an upgrade is needed at all, this guide to the signs your racking system needs an upgrade is a useful checklist.
Racking safety upgrades
Most racking failures start with something small: a forklift clipping an upright, a pallet pushed too far back or a beam loaded beyond its rating. These racking safety features are designed to stop those small incidents turning into serious ones.
Upright protectors and column guards
Uprights at the front of the racking take the majority of forklift impacts. Upright protectors, also known as column guards, fit around the base of each upright and absorb the force of a collision before it reaches the steel. They are one of the most cost-effective racking accessories available and should be fitted to every upright that faces a working aisle. Brightly coloured guards also make uprights more visible to drivers.
Racking safety barriers and rack end protectors
The ends of each run are particularly vulnerable because forklifts turn around them. Rack end protectors and racking safety barriers are heavy-duty steel barriers fixed to the floor at the end of each run. They stop vehicles striking the end frame, which can be one of the most damaging impacts a racking system can suffer.
Anti-collapse mesh
Anti-collapse mesh is fitted to the back of the racking to stop goods falling into an adjacent aisle or walkway. It is especially important where racking backs onto a pedestrian route, a picking area or another aisle where people work. Mesh panels can be fitted to the full height of the racking or to selected levels depending on the risk.
Mesh decking and timber decking
Decking provides a solid surface across beam levels for items that are not on pallets, or for pallets that are damaged or a non-standard size. Mesh decking allows light to pass through and lets sprinkler water reach lower levels, which is why it is usually preferred over timber in modern warehouses. Both options reduce the risk of items falling through the racking.
Pallet support bars
Pallet support bars sit front to back across a pair of beams to give extra support to pallets. They are useful where pallets are weak, of mixed sizes or placed in a different orientation to the one the racking was designed for. They reduce the risk of a pallet dropping between the beams.
Pallet stops
Pallet stops, sometimes called back stops, are fitted at the rear of a beam level to prevent pallets being pushed too far back. They stop pallets overhanging into the next aisle or blocking the flue space between back-to-back runs, which needs to stay clear for sprinkler effectiveness.
Row spacers and beam locks
Row spacers connect back-to-back runs and keep them correctly spaced and stable. Beam locks or safety pins stop beams being dislodged when a pallet is lifted. Both are small components, but missing or damaged ones are among the most common faults found during inspections.
Racking load signs
Every racking system should display load notices showing the maximum safe load per beam level and per bay. Racking load signs need to be clear, accurate and updated whenever the configuration changes. If beam levels have been moved or added since the racking was installed, existing signs may no longer be correct.
Efficiency upgrades
Safety upgrades protect your people and your stock. Efficiency upgrades help you get more from the space you already have.
Re-profiling beam levels
Adjusting the height of beam levels to match the pallets you store today can recover significant space. Racking designed around tall pallets may be wasting capacity if loads have become shorter. Re-profiling must always be checked by a competent person, because moving beams changes the load capacity of the frame. Load signs need updating afterwards.
Increasing storage height
If the building has clear height above the top beam level, it may be possible to extend frames or add another level. This depends on the capacity of the uprights, the floor slab and the reach of your forklifts, so it requires proper calculation before any work starts.
Converting to narrower aisles
Changing aisle widths can transform capacity. Moving from a wide aisle pallet racking layout to very narrow aisle (VNA) racking can increase the number of pallet locations in the same footprint significantly, although it requires specialist trucks and a high-quality floor.
Adding automated or high-density storage
For operations with large volumes of the same product, shuttle racking uses a remote-controlled shuttle to move pallets within deep lanes. It dramatically increases storage density and is particularly effective in chilled and frozen environments. For temperature-controlled sites, specialist cold storage racking with appropriate finishes protects against corrosion and condensation.
Upgrading finishes for harsh environments
Racking in cold stores, outdoor yards or damp environments can deteriorate faster than expected. Replacing or adding sections in a protective finish such as galvanised pallet racking extends the life of the system in these conditions.
Labelling and location systems
Clear location labels and barcodes on beams make picking faster and more accurate. They are an inexpensive upgrade that supports a warehouse management system and helps new staff find their way around quickly.
Lighting and floor marking
Good lighting in aisles reduces picking errors and collisions. Floor markings that separate pedestrian routes from vehicle aisles improve safety and help traffic flow more smoothly. Both are often overlooked when planning racking upgrades, but they make a real difference to how safely and efficiently the racking can be used.
How to upgrade pallet racking safely
Whatever the upgrade, the same principles apply:
- Assess the existing system through a full inspection and record any damage.
- Repair or replace damaged components before adding anything new.
- Use compatible components, ideally from the original manufacturer, to keep the system’s rated capacity valid.
- Recalculate loads whenever beam levels, heights or configurations change.
- Update load signs to reflect the new configuration.
- Train staff on any changes, especially new aisle widths or equipment.
- Schedule regular inspections so the upgraded system stays safe. BS EN 15635 recommends an expert inspection at least once every 12 months, alongside regular in-house checks.
Upgrades often work best as part of a wider plan. If several changes are needed at once, it may be worth reviewing the whole layout as part of a warehouse refurbishment.
Upgrade your pallet racking with Logical Storage Solutions
Logical Storage Solutions designs, supplies and installs pallet racking systems for warehouses across the UK, from adding safety accessories to existing racking through to complete reconfigurations.
Whether you need upright protectors and anti-collapse mesh fitted, beam levels re-profiled or a full redesign to increase capacity, the team can assess your current system and recommend the upgrades that will make the biggest difference.
Get in touch with Logical Storage Solutions to arrange an assessment and find out how to make your pallet racking safer and more efficient.