How to Design a Warehouse
Racking Layout.
Start with the space.
Plan around the warehouse before deciding what racking goes inside it.Where should warehouse racking design start?
When designing a warehouse racking layout, consider the building dimensions, pallet sizes and weights, forklift requirements, available height, stock profile, loading areas and future storage requirements.
Good warehouse racking design begins with the building and the operation, not with how many rack bays can physically be squeezed into the available space.
A layout needs to balance pallet capacity, access, handling efficiency, safety and operational flow.
1. Measure the warehouse accurately
Record the usable length, width and clear height of the warehouse as well as anything that may affect where racking can be positioned.
- Columns and structural supports.
- Pedestrian doors and loading doors.
- Fire exits and access routes.
- Services and fixed equipment.
- Loading and staging areas.
- Existing storage or machinery.
2. Understand what you are storing
Pallet dimensions
Record the width, depth and overall loaded height of the pallets.
Pallet weight
Maximum loads need to form part of the final racking specification.
Number of SKUs
The number of product lines and pallet quantities can influence whether direct-access or higher-density storage is more appropriate.
3. Determine the required aisle widths
Aisles can consume a significant proportion of warehouse floor area, so aisle width has a major impact on storage capacity.
The required width depends on the handling equipment, pallet dimensions, rack geometry and operating method.
The racking should be designed around the actual handling equipment or the equipment intended for the finished warehouse.
4. Choose the right racking system
The appropriate storage system depends on the stock profile, access requirements, handling equipment and available space. If you're still comparing the options, read our guide to the different types of warehouse racking .
Flexible direct-access storage for many palletised products.
Narrower aisles with direct pallet access.
Deep high-density storage for grouped stock.
Multiple-deep storage loaded from the aisle.
Long and bulky materials such as timber, pipe and steel.
Create additional usable floor space using warehouse height.
If you're considering direct-access storage, see our Selective vs VNA Pallet Racking guide .
For multiple-deep high-density storage, read our Drive-In vs Push-Back Racking guide .
5. Use warehouse height properly
Storage capacity is not determined by floor area alone. Available clear height can have a major impact on the number of pallet locations achievable.
Building structure, services, handling equipment lift height, pallet height and required clearances all need to be considered.
6. Design around warehouse flow
Consider how goods move from goods-in to storage, picking, staging and dispatch.
- Where do incoming pallets arrive?
- Where are they checked and staged?
- How do trucks reach the storage aisles?
- Where is picking carried out?
- Where are completed orders staged?
- How do pedestrian and vehicle routes interact?
7. Account for building obstructions
Columns, walls, equipment and services can affect where rack runs and aisles can realistically be positioned.
8. Allow for loading and staging areas
Filling every available metre with racking can make the warehouse less efficient. Operational space for unloading, checking, wrapping, picking and dispatch should be included in the design.
9. Think about future growth
Consider whether pallet numbers, SKU count, product dimensions or throughput may increase. A degree of future flexibility can sometimes be more valuable than maximising every pallet location immediately.
10. Review the layout before ordering
Review pallet quantities, access, aisle widths, forklift routes, loading areas, doors, columns and operational constraints before progressing to the final racking specification.
Ready to start designing your warehouse racking layout?
Use EasyDesign, EasyRack's online warehouse racking designer, to start planning your warehouse and provide us with the information needed to understand your project.
Warehouse racking layout FAQs.
What information do I need to design a warehouse racking layout?
Start with accurate warehouse dimensions, clear height, columns, doors, fixed obstructions, pallet sizes and weights, handling equipment and required pallet quantities.
How do you plan a pallet racking layout?
Start with the usable building dimensions and operation, then consider pallets, equipment, aisle widths, racking type, height, flow and loading or staging areas.
How wide should warehouse racking aisles be?
Required aisle width depends on the handling equipment, load dimensions, rack configuration and operating method rather than one universal measurement.
Which warehouse racking system gives the most storage?
Different high-density systems increase capacity in different ways. The most appropriate solution depends on stock profile, building dimensions and access requirements.
Should pallet racking be designed around the forklift?
The handling equipment and racking layout should be considered together because the truck's operating requirements influence aisle widths, lift heights and warehouse flow.
Can EasyRack help design my warehouse racking layout?
Yes. EasyDesign can be used to start planning your warehouse layout, and EasyQuote can be used when you're ready to submit the project for pricing.