See how Storeplan helped Aero Healthcare create a high-capacity distribution facility designed to improve storage, stock access and operational flow.
As part of its warehouse relocation in Armidale, Aero Healthcare needed significantly more capacity to support its growing product range and fast, accurate order fulfilment. Storeplan combined relocated existing racking with a new Schaefer I600 selective pallet racking system, creating more than 2,400 pallet spaces while improving access across receiving, storage, picking and dispatch.
Drag the slider to see what a properly planned layout does to the same floor space. The same building goes from underutilised and hard to work in to denser, safer and easier to pick from.
We'll come out, measure your space and design a system around it. No cost or commitment until you approve the quote.
The right pallet-racking system depends on the trade-off between storage density and access.
Storeplan recommends the layout based on your stock profile, picking requirements and available building height.
Get expert advice on the right pallet racking system for your operation. Free site assessment and custom design included.
Already know your requirements? Standard frame heights, beam profiles and load capacities are listed below.
If you’re not sure what you need yet, skip this and book a free measure instead.
Frames come in standard heights from 1850mm to 7550mm, at 838mm depth for standard pallets or 1200mm for larger ones.
Beam capacity depends on length and profile, ranging from 600kg per pallet space up to 3200kg per level.
| Height | Depth |
|---|---|
| 1850mm | 838mm |
| 2450mm | 838mm |
| 3050mm | 838mm |
| 3650mm | 838mm or 1200mm |
| 4250mm | 838mm |
| 4850mm | 838mm or 1200mm |
| 5450mm | 838mm |
| 6050mm | 838mm |
| 7550mm | 838mm |
| Beam Capacity | Capacity |
|---|---|
| 1381mm x U80mm | 2000kg per pallet space or level |
| 2600mm x U80mm | 625kg per pallet space, 1250kg per level |
| 2600mm x Tube 90mm | 1000kg per pallet space, 2000kg per level |
| 2600mm x Tube 98mm | 1200kg per pallet space, 2400kg per level |
| 2600mm x Tube 125mm | 1500kg per pallet space, 3000kg per level |
| 2752mm x U80mm | 600kg per pallet space, 1200kg per level |
| 2752mm x Tube 90mm | 1000kg per pallet space, 2000kg per level |
| 2752mm x Tube 98mm | 1200kg per pallet space, 2400kg per level |
| 2752mm x B105mm | 1500kg per pallet space, 3000kg per level |
| 3000mm x B105mm | 2800kg per level UDL |
| 3300mm x B105mm | 2400kg per level UDL |
| 3600mm x B105mm | 2000kg per level UDL |
| 3900mm x B150mm | 3200kg per level UDL |
Three straightforward steps from your first call to a finished, compliant racking system.
There is no cost or commitment until you approve the quote.
Storeplan reviews the warehouse, stock profile, access requirements and forklifts to understand what the space can realistically support.
Book a free site assessment and we'll measure your space, review your stock profile and put a system in front of you. No cost or commitment until you approve the quote.
Racking designed to improve capacity, access, safety and long-term performance.
Use your available height and floor space more effectively.
Reduce unnecessary pallet movements and picking delays.
Plan aisles and clearances around your handling needs.
Designed and installed to AS 4084:2023 with load signage supplied.
Plan future extensions before the first bay is installed.
Start with a free site assessment. No cost or commitment until you approve the quote.
The questions we’re asked most often before a racking project gets underway. If yours isn’t here, call the team. There’s no charge for advice.
It comes down to a trade-off between access and density.
Selective racking gives you direct access to every pallet. Any pallet, any time, no shuffling. It works with standard forklifts and suits most warehouses carrying a wide range of stock. The downside is aisles, since you need one between every pair of runs, so you get the least storage per square metre.
Double deep stores pallets two deep in each position, which roughly halves the number of aisles you need. You reach the back pallet by moving the front one, so it suits stock you hold in pairs or larger quantities. You’ll need a double deep reach truck rather than a standard forklift.
Drive-in packs the most in. Forklifts drive into the lane itself and pallets sit on rails, so there are no aisles between runs at all. It works on last in, first out, which makes it right for high volumes of the same product and wrong for anything with a short shelf life or a wide product range.
Most warehouses end up with a mix. Selective for picking, drive-in or double deep for bulk storage of the fast movers.
AS4084 is the Australian standard for steel storage racking. It covers design, load rating, installation tolerances, floor fixing, signage, damage assessment and inspection frequency.
Technically it’s a standard, not a law. In practice WHS regulators treat it as the benchmark for what a reasonably practicable duty of care looks like, so if something goes wrong and your racking doesn’t meet it, that’s the document you’ll be measured against. Insurers take the same view.
The parts that matter day to day are load rating signage displayed on every rack run, racking fixed to the floor to the design spec, damaged components taken out of service rather than patched, and a documented inspection routine.
Everything we design and install is built to AS4084, and we can assess existing racking that you’re not sure about.
Yes to both, but the specification changes.
Outdoors you want hot dipped galvanised components, not painted. Paint fails at the welds and the connector points, which is exactly where corrosion does structural damage rather than cosmetic damage. Galvanised racking handles rain, salt air and UV, and it’s what we use for yards, hardstands and covered outdoor storage.
Coolrooms and freezers bring different issues. Condensation and wash down regimes both attack finishes, so the componentry and fixings need to suit the temperature and cleaning routine. Layout matters more than usual too, since you’re paying to cool every cubic metre and you want the storage density up and the door open time down.
Yes, and it’s worth planning for at the design stage.
Racking is built in bays, so you can extend a run, add bays to the end, or add beam levels within the existing frames. Two things need checking when you do. The frame’s total rated capacity has to cover the extra load, and the floor fixings and slab have to handle the increase.
The catch is component compatibility. Beam and upright profiles vary between manufacturers, and connector types aren’t interchangeable. If you buy from one supplier now and someone else in three years, you may not be able to extend the original run. Worth knowing before you choose on price alone.
If you expect to grow, tell us at design stage. We’ll lay the system out so there’s a logical direction to expand in rather than boxing you into a corner.
Depends on your starting point, but the two questions worth asking are how high you’re currently going and how much of your floor is aisle.
Most warehouses are storing well below their available height, usually because the existing system was specified for the stock they had years ago. Going up is nearly always cheaper than going out.
Changing the racking type is the other lever. Moving bulk stock from selective to drive-in or double deep cuts aisle count and can lift pallet positions substantially in the same footprint, provided your stock profile suits it.
We do a free measure and quote, and part of that is telling you what the space could hold rather than just pricing what you asked for. If relocating is on the table, that comparison is worth having before you commit to a lease.
Choosing pallet warehouse racking is a trade-off between how much you store and how quickly you can reach it. We design around that, and around the building you already have.
Selective pallet racking is the most common system we install. Every pallet is directly accessible and it works with standard forklifts, which suits most warehouses carrying a wide range of stock.
Where storage density matters more than access, double deep racking stores pallets two deep and cuts the number of aisles you need. Drive-in racking goes further again and suits high volumes of the same product, where forklifts drive into the lane itself.
For long, heavy or awkward stock such as timber, steel or pipe, cantilever racking removes the front upright entirely. Conduit racking and cable racking handle electrical stock, and galvanised pallet racking is built for outdoor yards.
We also install Very Narrow Aisle (VNA) racking where floor space is tight and you need to build height.
Get expert advice on the right pallet racking system for your operation. Free site assessment and custom design included.
