What do pallet racking projects cost?

Pallet racking is engineered on a project-specific basis with no fixed standard cost. Key investment factors include required pallet capacity, ceiling height, bay and beam load profiles, forklift handling systems, seismic criteria, and specific accessories. DEXION RACKING provides custom feasibility studies and transparent quotations with rapid response times.

How long does a pallet racking installation take?

From engineering design approval to commissioning, a standard turnkey project typically takes 8 to 16 weeks depending on structural complexity, site readiness, and local safety permitting. System upgrades or standard bay expansions can be delivered significantly faster.

Can existing racking be expanded or modernized?

Yes. Existing installations built to standard structural tolerances can often be expanded or reconfigured. Warehouses utilizing the P90 profile can be upgraded directly with additional bays, higher uprights, dense shuttle lanes, or automated interfaces.

How is the racking prepared for future warehouse automation?

The DEXION RACKING P90 platform is designed from inception to support automated guided vehicles (AGVs), autonomous mobile robots (AMRs), pallet shuttles, and stacker cranes. Strict roll-forming tolerances ensure structural stability under mechanical dynamic loads.

How often should pallet racking inspections be conducted?

Under international safety standard EN 15635, formal inspections by certified racking experts must take place at least once every 12 months. Routine visual checks by an internal safety coordinator should be conducted weekly or monthly.

Can DEXION RACKING systems be integrated into operating warehouses?

Yes. Turnkey retrofit projects are routinely performed in phased schedules to preserve uninterrupted logistics workflows, allowing ongoing picking and shipping operations during assembly.

Pallet Racking Solutions & Engineered Storage Systems

DEXION RACKING P90 Platform

Industrial Racking Engineered for Load Integrity & Growth

Built to international structural standards including EN 15512, FEM, and ISO, the P90 modular system maximizes vertical height, streamlines aisle management, and prepares logistics sites for future automated handling.

30 Tonnes

Maximum Upright Bay Load Capacity

5 Tonnes

Maximum Beam Pair Load Limit

Up to 30m

High-Bay Rack Height Capability

Up to 20%

Density Gain via Layout Re-engineering

Scalable Modular Design

Standardized upright pitches and universal beam connectors allow seamless bay adjustments, height extensions, and picking level re-profiling without system replacement.

50mm vertical slot adjustment
Compatible with wire mesh & steel decking
Quick boltless beam locking pins

Industrial Load Integrity

Manufactured using certified structural coils with full batch traceability. Engineered with finite element analysis (FEA) to resist dynamic forklift impact and local seismic stresses.

Full EN 15512 & SEMA compliance
Standard hot-dip galvanized or RAL powder coat
Certified laboratory verified stress curves

Automation & AGV Ready

Precision-milled rail alignments and deflection-tested steel profiles accommodate autonomous mobile robots (AMRs), automated shuttles, and narrow-aisle stacker cranes.

Tolerances calibrated for robotic picking
Compatible with pallet shuttle systems
Integrates with automated WCS/WMS networks

Engineered Configurations

Pallet Racking Systems Designed for Operational Throughput

Select the racking architecture aligned with your SKU profiles, pallet rotation protocols (FIFO/LIFO), and fleet equipment.

Selective Pallet Racking

The industry benchmark for 100% immediate selectivity. Ideal for distribution centers handling high SKU counts, variable pallet footprints, and quick stock turnover.

DEXION RACKING Mobile Pallet Racking System

Mobile Pallet Racking (MOVO)

Racks mounted on motorized rail bases eliminate fixed aisles, cutting required footprint by up to 45% while preserving direct access to every pallet position. Suited for cold storage.

Pallet Shuttle Systems

Semi-automated deep-lane pallet runners handle high-density lane loading and unloading via remote control, reducing forklift travel distance and vehicle exhaust emissions.

DEXION RACKING Mega Distribution Center Project

Case Benchmark

Global Fulfillment Hub

High-Density Retail & eCommerce Distribution Facility

A flagship 110,000 m² distribution hub commissioned with custom-engineered DEXION RACKING P90 systems. The installation combined heavy-duty wide-aisle pallet storage with multi-tier mezzanine picking zones, delivering robust throughput during peak fulfillment cycles.

110,000 m² Facility Floor Plate

145,000 Pallet Positions

16,500 m² Mezzanine Shelving

Delivered via phased handovers with certified installation oversight to ensure uninterrupted facility start-up and complete health & safety compliance.

Structural Component Profiles

Precision Steel Profiles Engineered to Load Criteria

Beam sizing and frame geometries are calculated using structural analysis to guarantee deflection limits well within EN 15512 safety ratios.

Profile Type	Standard Profile Heights	Primary Application	Surface Finish Options
P90 Box Beam	60mm – 160mm	Universal pallet racking, heavy euro-pallet and industrial load support	Hot-dip galvanized / RAL powder-coated
P90 Open Beam	50mm – 75mm	Drop-in timber decks, wire mesh shelves, custom container cradles	Corrosion-resistant galvanized
Silverline I-Beam	100mm, 125mm, 140mm	Cost-optimized long-span distributed loads and standard storage runs	Hot-dip galvanized steel
Heavy IPE / Sigma Profiles	Custom calculated	Extreme heavy bay loads, integrated crane structures, and clad-rack buildings	Industrial anti-corrosive primer & topcoat

Turnkey Project Delivery

From Structural Survey to EN 15635 Inspection

A documented engineering execution methodology mitigating technical risk for overseas procurement teams and main contractors.

Phase 01

Consulting & Site Analysis

Detailed evaluation of pallet dimensions, load weights, floor slab capacities, forklift mast reach, and fire suppression clearances.

Phase 02

Structural CAD & Static Calculations

Complete layout drawings with FEA load-distribution analyses verified against Eurocode and local building seismic mandates.

Phase 03

Automated Manufacturing

Industrialized roll-forming and robotic welding across company-owned production facilities, ensuring uniform dimensional accuracy.

Phase 04

Certified Site Erection

Turnkey assembly supervised by certified engineers, adhering to rigorous zero-harm safety practices and structural alignment tolerances.

Phase 05

Load Testing & Commissioning

Systematic handover documentation including official load capacity signage, bay data placards, and operational maintenance manuals.

Phase 06

Annual EN 15635 Audits

Comprehensive ongoing structural health inspections by accredited inspectors, issuing detailed green/amber/red safety assessments.

Frequently Asked Questions

Pallet Racking Technical & Procurement FAQ

Clear answers from our technical engineering desk on planning, sizing, and lifecycle compliance.

What factors determine the cost of a pallet racking installation?

Pallet racking is engineered on a project-specific basis. Project investment depends on overall pallet position volume, clear warehouse height, floor slab load ratings, bay load profiles (from 500 kg to over 4,000 kg per level), handling machinery aisles, and accessories such as column guards or mesh screens. We provide detailed layout studies and pricing assessments within rapid response schedules.

What is the typical lead time for a complete pallet racking project?

Standard customized installations generally require 8 to 16 weeks from approved structural drawings through manufacturing, site delivery, and completed assembly. Minor bay expansions or standard retrofit configurations can often be fulfilled considerably faster from available profile inventories.

Can our existing warehouse racking be retrofitted without halting operations?

Yes. Most modernization and expansion projects are engineered in localized, phased stages. Our certified installation specialists cordon off specific aisles, re-profile beam heights, or add high-density shuttle runs while your warehouse team maintains standard shipping and receiving in adjacent bays.

How does the P90 system support future warehouse automation?

The DEXION RACKING P90 architecture is designed with precise roll-forming tolerances that accommodate automated pallet shuttles, autonomous mobile robots (AMRs), and stacker cranes. A facility can start with standard forklift selective racking and upgrade to semi-automated deep-lane or automated storage without dismantling the existing upright framework.

What are the mandatory inspection standards for pallet racking systems?

International safety standard EN 15635 dictates that industrial steel storage systems undergo annual formal technical inspections by a qualified, independent inspector. Operators are also expected to carry out routine internal inspections to identify beam deflection, twisted uprights, or damaged base plates before failure occurs.

Pallet Racking Solutions