The information your supplier needs for a pallet-racking installation

To plan a pallet racking layout, your supplier needs loaded pallet dimensions, weights and quantities, forklift specifications and a plan of the warehouse. They also need to understand how frequently stock is accessed and how goods move through the building.

The building dimensions come next. They show the space available, but the operational details establish how that space can work for you. Sending both sets of information helps your supplier develop a layout and quotation around your actual requirements.

Here at Penwright, we use those conversations and a site visit to understand the brief before preparing the proposed warehouse storage layout.

What stock information does a pallet racking layout need?

Your supplier needs the loaded pallet dimensions, maximum weights, required pallet positions and the way stock is picked and replenished. Separate different load types so the racking design reflects what you actually handle.

Which pallet dimensions and weights should you record?

Record the pallet's width and depth, overall loaded height and maximum loaded weight, including the pallet. Include any product or wrapping extending beyond the pallet, and explain which way round you intend to store and handle it.

“Standard pallets” is not a precise enough description. You may receive several pallet formats, or loads that use the same base but have different heights and overhangs. Where that happens, separate the main types in your brief.

For each type, record:

• Pallet dimensions and the overall dimensions of the loaded unit.

• Typical and maximum loaded weight, including the pallet.

• The number of pallet positions required.

• Whether quantities or load sizes change at particular times of year.

Use measured or recorded information wherever possible. If a figure is an estimate, identify it as such so it can be checked before the specification is agreed.

How does stock movement affect the racking design?

Picking, replenishment and the frequency of access determine how readily each stock line needs to be reached. Explain whether you move complete pallets, pick individual products or use a mixture of both, and which lines are accessed throughout the day.

For example, a warehouse holding a few product lines in large quantities has a different brief from one holding many lines with only one or two pallets of each. The total pallet count might be similar, but the access requirements can be quite different.

Include expected growth in the discussion. Explain whether you anticipate more of the same stock, new product sizes or a change in picking activity. This helps separate the capacity you need immediately from provision worth considering for later.

Which building and handling details affect the layout?

The available floor space and height, fixed obstructions, floor support, access routes and forklift requirements all affect the layout. These details establish where racking can be positioned and the room needed to use it.

Why does your supplier need the forklift specification?

The forklift specification helps establish suitable aisle space, lifting heights and load-handling requirements for the pallet racking layout. Provide the truck's make, model, specification and attachment details, including each relevant type if you use several trucks.

This allows the designer to assess the handling requirements against the proposed racking. A truck's stated maximum capacity should not be taken as confirmation that it can handle every load at every proposed height.

If you intend to replace the forklift as part of the project, discuss the equipment and racking together. Choosing one without checking the other can leave you with a layout that does not suit the operation.

Which warehouse areas need to remain clear?

Allow space for doors, pedestrian routes, handling equipment and access around fixed obstructions such as columns, stairs and offices. Mark these on a floor plan, even if it is an existing drawing that needs checking on site.

Include the spaces you need to keep for receiving goods, checking deliveries, packing, despatch and temporary stock. These areas can be easy to overlook when the initial aim is to increase pallet positions.

The survey also needs to consider the floor, available height, building services and routes through the warehouse. HSE's warehousing guidance identifies suitable floor support and adequate room for handling equipment as key considerations for racking installation. Aisle dimensions and clearances need to be established for the particular system and equipment.

How should a pallet racking layout balance capacity and access?

A workable pallet racking layout reserves space for handling, picking, goods-in, despatch and pedestrian routes before allocating the remaining area to pallet positions. Explain any existing problems, such as blocked picking areas or excessive stock movements, so the design addresses how the warehouse operates.

Consider a warehouse where fast-moving lines sit at the far end of the building while incoming pallets regularly occupy the nearest aisle. Adding another row of racking might create more positions without resolving either problem. Reviewing the locations of those activities could make the extra capacity more useful.

That is why a proposed drawing needs reviewing with the people who use the warehouse. Ask where a delivery will wait, how replenishment will take place and how an order reaches despatch. Identify pedestrian routes and any points where different activities compete for space.

Discuss practical trade-offs openly. A layout with fewer nominal positions may work better if it gives you the access and working space your stock requires. The appropriate balance depends on your operation rather than a general target for the number of bays.

What should you send before a pallet-racking site visit?

Before a pallet-racking site visit, send a warehouse plan or sketch, pallet dimensions and weights, required quantities, forklift details and a summary of how you handle stock. Include the following in your brief:

• The site address, contact details and reason for the project.

• A plan or sketch, approximate dimensions and photographs of the area.

• Pallet sizes, loaded heights, weights and required quantities.

• Forklift makes, models, specifications and any planned equipment changes.

• An explanation of picking, replenishment and goods-in and despatch activity.

• Existing racking drawings or records if equipment is to be retained.

• Your preferred timing and restrictions on access or installation work.

Do not delay an initial conversation because one item is missing. Tell us what you know and what still needs establishing. Identifying a missing load weight or equipment specification early gives you time to obtain it.

How Penwright develops your pallet racking layout

At Penwright, we develop your pallet racking layout from the information and sketches gathered during the site visit. We prepare a drawing for discussion so you can review the proposed arrangement and agree the details before supply and installation.

Our storage design and installation service covers commercial projects for businesses in London and the surrounding areas. Contact the team to discuss your racking requirements, or call 020 8880 1919, with your plans, stock information and a brief explanation of what needs to improve.