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Pallet Racking Installation Guide

United Racking recommends that all Pallet Racking is installed by an experienced installer with knowledge of the Australian Standard AS4084-2012. Please use the below information as a guideline only and be sure to speak with your local United Racking representative if you have any questions or are unsure if your installation will meet the strict standards.

This install guide shows the safe installation of a "2-Bay Run" of Selective Pallet Racking with two beam levels.

Pallet Racking
Pallet Racking

Parts List:

3x Pre-assembled Upright Frames

8x Horizontal Beams

16x Beam Safety Locking Pins

2x U-Shape Frame Guards

20x Base Anchors (Dana-Bolts)

1x Safety Sign

Levelling Plates (Shims)

Tools Required:

Hammer & Rubber Mallet

Hammer Drill

Impact Rattle Gun 

Socket Set

Tape Measure

String Line

Spirit Level

Important Information

  • A minimum of two people are required for the safe installation of Pallet Racking

  • The floor should be level and suitable for the system.

  • Pallet Racking "MUST" be secured to the floor with suitable anchors.

  • Load ratings are dependent on the design and products used.

  • Always use suitable lifting equipment like Scissor Lifts or Forklifts with a safety cage. NEVER climb on the frames. 

Pallet Racking

Step 1.

To begin, ensure you accurately measure the desired distance between the racking and the wall. We suggest a minimum of 300mm, taking into account any columns or obstacles such as power points or light switches. Remember, this allowance allows sufficient space for the pallet to extend beyond the rear of the system. Before commencing the installation, use a string or chalk-line to mark the designated location.

Pallet Racking

Step 2.

Next, erect the initial frame and position the first beam in the front section at its lowest point. While you can make adjustments to the beam levels later on, it is essential to have it placed in the lowest position during this stage of the installation process. Ensure that you securely install the locking pin to firmly fasten the beam in place.

Pallet Racking

Step 3.

With the help of an assistant, carefully lift and position the second frame into its designated location. Proceed to complete the installation of the first beam, ensuring it is securely fastened with the locking pin.

Pallet Racking

Step 4.

Having successfully positioned two frames and one beam, it is now time to install the second beam. Align it with the first beam, making sure it is level, but in the rear position. Remember to firmly insert the beam locking pins to ensure the beam is securely locked in place.

Pallet Racking

Step 5.

Proceed to install the second level of beams to finalize the construction of the first bay. Ensure that you meticulously install all beam locking pins to guarantee the secure attachment of the beams.

Pallet Racking

Step 6.

With the first bay successfully assembled and secured, proceed to erect the third and final frame. Repeat steps 2-5 to complete the construction of the second bay. Keep in mind that beam levels can be adjusted later, focus on ensuring the beams are secured to the frames with safety locking pins in place.

Pallet Racking

Step 7.

Once the entire system is assembled, ensuring its alignment and squareness is crucial. To achieve this, measure the distance diagonally from one corner of a beam to the opposite corner (refer to the provided illustration for clarity). This measurement will determine whether the bay is square and ready for levelling. If one diagonal measurement is larger than the other, make the necessary adjustments until both measurements are identical, ensuring a perfectly square configuration.

Pallet Racking
Pallet Racking

Step 8.

Now that the rack is squared up, it's time to focus on achieving proper levelling. Utilize a spirit level or a similar levelling device to ensure both the vertical frames and horizontal beams are level. If adjustments are necessary, utilize base plate shims specifically designed for the frame being used. Selecting the appropriate shim plates manufactured for the frame model is crucial. Shims are available in 1mm and 3mm heights and can be conveniently obtained from your local United Racking branch.

Pallet Racking

Step 9.

At this crucial stage of the installation, it is essential to thoroughly double-check all aspects of the system. Verify that the system has remained in place without any unintended movement. Additionally, ensure that all measurements and leveling are accurate and in line with the required specifications. Once you are confident that everything is perfectly aligned and in order, you can confidently proceed to the next step.

Pallet Racking

Step 10.

To securely fasten the base plates to the floor, utilize a suitable hammer drill, hammer, and socket. Drill holes in the floor and then install anchors using the provided hardware. It is crucial to ensure that each base plate is firmly anchored with a minimum of two (2) suitable floor anchors per base plate. This step ensures the stability and safety of the rack system. Now that everything is bolted down you can adjust the lower beam level to the desired height.

Pallet Racking

Step 11.

For the end frames (far left and far right), it is necessary to install frame protectors. Similar to the base plates, these frame protectors must be securely anchored to the floor using appropriate anchors such as Dyna-Bolts. Ensure that the frame protectors are firmly attached to provide additional stability and protection for the end frames.

Step 12.

Installing the load signage is a straightforward process, but it must be done accurately. Position the sign at a height of 1500mm above the floor. It is crucial that the installer completes the sign with the appropriate information. For the specific details and information required on the sign, please reach out to your United Racking representative. They will provide you with the necessary instructions to ensure the sign is filled in correctly.

Pallet Racking
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