REPAIR
Start with the affected area
Bent, twisted or impacted components should not be treated as a cosmetic issue. We can document the affected area and coordinate a qualified repair or replacement path around the actual system.
Pallet Racking Planned Around Your Operation
Two3 Solutions plans, sources and installs pallet racking for warehouses and manufacturing facilities, with used rack available as an option for certain projects. We design layouts around your inventory, pallet loads, forklifts and available space, then coordinate equipment sourcing and installation. Based in Brookfield, Wisconsin, we complete projects nationwide.
PALLET RACKING
What Does the Right Pallet Racking System Help You Do?
Add Pallet Positions
Use your warehouse's vertical space and available floor area more effectively with a pallet-racking layout designed around your inventory.
Improve Access and Flow
Plan rack placement, aisle widths and storage methods around your forklifts, picking needs and how products move through the facility.
Plan for What Comes Next
Build a pallet-racking system that can support changing inventory, equipment and operational needs.
WHAT DETERMINES A PALLET RACKING LAYOUT?
Clear Height
One factor in determining how high we can design the system, with another being the top reach of the forklift.
Beam Length
Product dimensions dictate the beam length and required capacity ratings.
Flue Space
The space between 2 frames. Maintaining proper flue space is important in order to stay compliant with local code.
Decking
Product dimensions and pallet type dictate what type of decking is used. It's imperative to understand this prior to adding to your system.
Upright Frame
The frame depth is determined by the depth of the product. Not every frame is the same - it should be tailored to your product mix and weights.
Vertical Beam Spacing
The vertical distance between each level. This is crucial to determining upright frame capacity. The wider the span, the heavier the frame!
Building Columns
It's nearly impossible to avoid having building columns in your space. However, "hiding" the columns within the flue space is the goal. Anything to keep the building columns from impeding forklift aisles.
Aisle Spacing
The forklifts determine the aisle spacing. Do not forget about the forklift when designing your racking system!
End of Aisle Guard
Protect the end of your racking aisles with End of Aisle Guards.
Post Protector
Be proactive when it comes to safety. It's common for forklift operators to damage upright frame. Reduce the impact on the frames and add post protectors.
What Do We Need to Plan Your Pallet Rack Layout?
A useful pallet rack layout starts with your product, equipment and building information. Share what you have available, and our team can help identify what still needs to be confirmed.
- Pallet dimensions, loaded heights and weights
- SKU count, inventory quantities and pallet access needs
- Forklift model, lift height and operating requirements
- Building drawings, clear heights, columns, doors and work areas
- Existing rack condition, specifications and documentation
- Growth plans, installation timing and operational constraints
This information starts the planning conversation. The proposed configuration still requires the applicable design, engineering and permitting reviews.
Which Pallet Racking System Fits Your Operation?
The right system depends on how many pallets you store per SKU, how often they move and how much direct access your team needs.
Selective Pallet Racking
Single-deep selective racking provides direct forklift access to each pallet position. It suits a broad SKU mix when individual pallet access matters more than deep-lane density. Aisles and beam levels must fit the equipment and loads.
Pushback Racking
Pushback stores multiple pallets of the same SKU in each lane on nested carts or rollers. Loading and unloading take place from the same aisle, following last-in, first-out (LIFO) rotation. It can suit several pallets per SKU where strict FIFO rotation is not required. Explore pushback racking.
Pallet Flow Racking
Pallet flow uses inclined roller lanes to move pallets from the loading side toward a separate picking face. This supports first-in, first-out (FIFO) rotation. Pallet construction, load characteristics and flow-control components must be matched to the application. Explore pallet flow racking.
Pallet Runner
Pallet Runner uses a powered shuttle to move pallets within deep storage lanes while a forklift handles pallets at the lane entrance. It is a semi-automated option for storing multiple pallets per SKU. Lane depth, pallet compatibility, replenishment and retrieval rates shape the configuration. Explore Pallet Runner.
EXISTING PALLET RACK
Repair, reuse, reconfigure or replace?
The right answer depends on what changed. Damage, new loads, capacity pressure and an upcoming move do not point to the same scope. We review the system in the field before recommending the next step.
REUSE
Confirm what belongs in the next layout
Existing rack may be reusable when its condition, manufacturer, capacity, documentation, component compatibility and proposed configuration all support it. Field verification comes before the layout.
RECONFIGURE
Treat the change as a complete system
Moving beam levels, changing bay widths or creating a new aisle plan can change loading, clearances, protection and permitting needs. The updated layout should be reviewed as a complete system.
REPLACE
Replace what no longer fits
Replacement can make sense when components are damaged, undocumented, incompatible, insufficient for new loads or costly to work around. We compare the scope before material is ordered.
AN OPTION FOR SELECT PROJECTS
Used pallet rack, when it fits the job
Used pallet racking may be an option for certain warehouse projects when suitable material is available. Two3 can help evaluate whether pre-owned rack fits your layout, pallet loads and schedule, or whether new racking is the better choice.
The decision goes beyond beam length and upright height. Component condition, manufacturer and connection compatibility, beam elevations and documented load capacity all matter. Similar-looking rack components should not be assumed interchangeable.
Availability, quantities and sizes vary by job. Share your pallet dimensions, maximum pallet weight, required positions and installation location so we can discuss a practical direction.
Application photo is illustrative and does not represent available used inventory.
- Confirm condition and component compatibility before planning reuse
- Verify capacity for the proposed configuration and pallet loads
- Compare the complete installed scope, including freight and any required engineering or permits
RACKING PROJECTS PLANNED FOR REAL OPERATIONS
Every facility brings a different mix of inventory, building constraints and installation requirements. See how Two3 has approached recent pallet-racking projects.
For a southeast Wisconsin planning example, see how a second measurement changed a Waukesha pallet-rack layout before equipment was ordered.
RECENT SOLUTION SPOTLIGHT
192,000 SQ FT DISTRIBUTION FACILITY FROM ABOVE
This drone video captures the scale of a large warehouse racking project in Sussex, WI. When complete, the 192,000 sq ft distribution facility will hold just shy of 10,000 pallet positions. The aerial perspective helps show how the system is coming together across the full footprint, giving the customer a clearer view of progress, layout, and scale than floor-level footage alone.
RECENT SOLUTION SPOTLIGHT
TURNKEY RACKING SYSTEM
This completed pallet racking installation helped a medical furniture manufacturer add 2,200+ pallet positions across more than 30,000 sq ft in the Milwaukee area. With the customer now live, the catwalk surrounding the racking system gives a unique overhead look at the finished layout, wire decking, anchored rack rows, and organized storage capacity now supporting daily operation.
System in Action
A recent turnkey install included custom-specified pallet racking for their product, shelf-supported racking, carton flow, a secured wire cage for specialty items, and guardrail protection around the exterior of the build. The result is a layout built for higher-density storage and faster, cleaner access at the pick face, with added protection where impact risk is highest.
MORE THAN PALLET POSITIONS
Rack-supported mezzanines: take your storage plan up a level
If your rack project also needs elevated picking or storage space, a rack-supported mezzanine can integrate the floor with the storage structure. The rack becomes part of the engineered support system, so pallet loads, floor loads and the load path to the slab must be evaluated together.
This approach can combine lower-level storage with upper-level picking areas and, where the workflow calls for it, carton flow or conveyors. Two3 helps plan the rack and elevated level as one system.
- Design rack frames, floor framing and connections for combined storage and platform loads
- Coordinate bay spacing, replenishment aisles and pedestrian access between levels
- Assess existing rack before considering reuse; a standard rack rating alone is not enough
Pallet racking resource
Download the Pallet Racking Planning Guide
Use this two-page guide to review common rack system options, the warehouse and product factors that shape a layout, and how Two3 plans, sources and installs a pallet-racking system.
Download pallet racking guide
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