Pallet Rack Types & Styles

Ever walked into a huge warehouse and wondered how everything stays organized on those towering shelves? Or how managers decide which rack system to use in different parts of a warehouse? Pallet rack systems are the secret behind efficient storage. What holds up those heavy pallets and boxes overhead?

It all comes down to selecting the right rack style. New terms like drive-in rack or cantilever rack might sound exotic at first, but we’ll explain them. We will see the different Pallet rack types & styles that businesses use to make the most of their space. Stay curious, because by the end, you’ll know how to pick the right rack for your goods and where to get forklifts and parts for them.

Why Pallet Racks Matter

Warehouses and industrial facilities use pallet racks to hold many palletized goods (wood or plastic platforms carrying boxes or items). Good pallet racking maximizes storage space and keeps goods safe and easy to find.

Without the right racks, operations slow down and space goes to waste. Imagine forklifts driving extra miles or having to backtrack because aisles are wrong; it can also increase the risk of collisions. In this guide we’ll cover each major rack style and its ideal uses.

Teardrop & Keystone: The Connection Styles

Before we get into the big systems, let’s talk about how they’re put together.

Teardrop Racking is the most popular style in the U.S. for a reason. Its upright frames have teardrop-shaped holes. The beams just click into place without any tools. Think of it like a giant Lego set for your warehouse. It’s fast, easy to adjust, and you can often mix and match parts from different brands.

Keystone Racking is also called Republic style, which uses keyhole-shaped slots. The beams lock in tight, creating a super sturdy and secure connection. While it’s very strong, it’s less common, so you’ll need to stick with the same brand if you want to add on later.

Selective Pallet Racking: The All-Rounder

Selective pallet racking is the most common rack you’ll see. Imagine a library where you can walk down any aisle and grab any book you want. That’s selective racking. It gives you direct, 100% access to every single pallet, anytime.

The trade-off? You need an aisle for every row, which eats up floor space. But if you have a lot of different products and need to get to them fast, this is your simple, reliable, and cost-effective go-to.

Double Deep Racking: The Space Saver

Think of this as a clever upgrade to selective racking. Instead of storing one pallet, you store two, one right behind the other.

This simple trick can boost your storage space by up to 40% because you need fewer aisles. The catch is that you can’t reach the back pallet without moving the front one first. It’s perfect for storing large batches of the same item and works best if the last thing you put in is the first thing you take out (LIFO).

Drive-In & Drive-Thru Racking: The Density King

Want to pack in as much product as humanly possible? This is your answer. These racks let forklifts drive directly into deep storage lanes, turning aisle space into storage space.

• Drive-In is like a garage with one door. The last car in is the first one out. It offers incredible density and is great for storing huge amounts of the same product.
• Drive-Thru is like a garage with a front and back door. You load on one side and unload on the other, making it perfect for products that need to be rotated, like food (FIFO).

Push Back Racking: The Best of Both Worlds

Push back racking gives you great density and flexibility. Pallets sit on carts that glide on rails. When you load a new pallet, you gently push the others back. When you take one out, the rest roll forward.

This gives you dense storage but still lets you store a different product on each level, which you can’t do with drive-in racks. Many consider it the perfect compromise between saving space and accessing your goods.

Pallet Flow Racking: The Automatic Choice

Imagine a soda dispenser at a convenience store. You grab one, and the next one slides right into place. That’s exactly how pallet flow works, but for pallets.

You load from the back, and gravity gently rolls the pallets to the front for picking. It’s the ultimate First-In, First-Out (FIFO) system. If you handle food, drinks, or anything with an expiration date, this system is the gold standard for keeping things fresh and moving.

Cantilever Racking: The Specialist

What if you’re storing things that don’t fit on pallets? Think lumber, pipes, steel tubing, or big rolls of carpet. That’s where cantilever racking shines.

It has no front columns to get in the way, just long arms sticking out to hold your bulky items. It’s the perfect solution for anything long, awkward, or oversized.

Structural Pallet Racking: The Heavyweight Champion

This isn’t a type of system, but rather how it’s built. Instead of thinner, roll-formed steel, structural racking is made from heavy-duty, solid steel channels, the same stuff used to construct buildings.

How to Choose the Right Rack

With so many Pallet Rack Types & Styles, how do you pick the best one? Consider your inventory and workflow:

• Many different SKUs or mostly identical goods?
• Do you need First-In-First-Out (FIFO) or Last-In-First-Out (LIFO) flow?
• How often must you access each pallet?

If you need 100% selectivity (immediate access to any pallet), go with Selective Racking. If your items are similar and space is critical, Drive-In or Push-Back might fit. For high-turnover FIFO inventory, Pallet Flow is ideal. For long, bulky items, choose Cantilever.

Match the rack style to your product and picking speed. Plan aisles wide enough for safe forklift operation, and always check weight limits. Remember, rack installations often need to meet local building codes and engineering standards.

For example, a distribution center with many SKUs may use selective racks, while a cold storage warehouse might use drive-in or flow racks for bulk pallets.

Getting Equipment and Parts

Once your rack layout is planned, you need the right forklift. Choose forklifts with the height and capacity for your racks. If you don’t have the right forklifts, rent a forklift at MDSIndustrialCorp.com. MDS Industrial rents many types of forklifts (electric, LPG, diesel) to match your needs.

Maintenance is key too. Worn forklift components can slow down your operations. If you need forklift parts (forks, tires, batteries, etc.), MDS forklift parts can supply them. Keeping your forklift fleet in top shape means your pallets keep flowing smoothly, no matter which rack system you use.

Conclusion

Choosing the right Pallet Rack Types & Styles makes your warehouse work faster and safer. In this blog, we covered:

Each style has a purpose. Think about your products, inventory turnover, and space needs. With the right rack system and reliable forklifts (rented or owned), you’ll turn any warehouse into an organized, efficient storage space. For heavy equipment, remember MDS Industrial offers forklift rentals, and MDS forklift parts has the replacement parts you might need.