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Full indoor shot of a large warehouse or cold storage facility. Metal racking systems, painted red, are arranged in tightly spaced, double rows. The racking system spans the entire image width, creating a long, narrow aisle down the center. Yellow plastic or rubber bumpers/protectors are attached to the concrete floor along the bases of all the metal racking columns. The image's focus is on the structural design and organization of the storage space, with a clear view of the metal framework and the defined aisle in the center. Industrial efficiency and robust storage capacity with AJ Products racking shelves

How to build and expand your warehouse racking system: A simple guide

Looking to install or extend your warehouse racking system? Whether you're setting up storage for the first time or upgrading your space to meet growing demand, understanding the building blocks of racking is key to creating a safe, scalable and efficient storage solution.
In this guide, we’ll explain the difference between basic and add-on units, how to build a racking run, and why modular shelving can help your business save space and money in the long term.
A multi-tiered metal shelving unit by AJ Products. racking shelving unit composed of vertical metal support beams, horizontal red metal beams connecting the supports, and wire mesh storage baskets or containers at several levels. Yellow plastic corner protectors are affixed to the base of the unit. The image is well-lit, and the background is pure white.
  • Two end frames (or four vertical posts , also called uprights)
  • A set of shelves or beams, depending  on wheter you're storing items directly or using pallet racking 
  • Cross bracing if needed, this adds extra stability to prevent wobbling
  • One end frame (or two uprights) 
  • A set of shelves or beams
  • Cross bracing if needed
well-organized, industrial storage and distribution area with metal racking systems, with red supports and gray metal beams holding numerous carboard boxes and wooden pallets
a man working in a large warehouse. He is pulling a wooden pallet using a metal handle. The pallet is part of a system of metal racking and shelving storage.
The installation area needs to be properly prepared. Clear the space of packaging, debris, or old shelving to ensure there’s nothing that could get in the way. It’s vital to check that your floor is level and structurally sound - uneven or unstable flooring can lead to instability or long-term safety issues. Depending on the size and type of racking you’re installing, you may also need access to specific tools, a ladder, or even lifting equipment. Having all materials and components ready to go before you begin will make the process smoother and faster.
Racking and shelving systems may appear simple, but they are engineered for specific loads and configurations. Always follow the assembly instructions provided by the manufacturer. Be cautious not to mix brands or substitute components unless they’re specifically designed to be compatible. Bolts, beams, and braces all play a role in structural integrity, so it’s essential to install them correctly. Fasten all fittings securely, but avoid overtightening, which could damage the parts or affect load-bearing capacity.
One of the most overlooked, but critical, aspects of racking installation is proper anchoring. In most cases, especially for high or heavy-duty racking, floor anchoring is a legal and safety requirement. Anchors must be suited to your specific floor type, whether it’s concrete, slab, or another material. In some installations, additional measures such as wall ties or cross bracing may be needed to improve lateral stability. Anchoring not only helps prevent tipping or collapse but also protects against damage from forklift bumps or daily wear and tear.
Safe load distribution is key to maintaining structural integrity over time. As a general rule, heavier items should be stored on the lower levels, with lighter goods placed higher up. This helps to lower the centre of gravity and reduce the risk of tipping. Avoid overloading any one shelf, and ensure the total weight remains within the racking’s specified capacity - this information should be clearly stated in the manufacturer’s technical data. Spreading the weight evenly across the beams or shelves will also prevent bowing or distortion under pressure.
It’s also a good idea to fit load notices to each bay, indicating the maximum shelf and bay capacities - this is not only good practice, but a requirement under UK workplace safety guidelines. Ongoing safety is just as important, so be sure to schedule regular inspections to check for any damage, movement, or wear over time. Staff should be trained on how to use the racking safely, how to stack items securely, and how to report any concerns or impact damage promptly. A well-maintained racking system not only extends product lifespan but also reduces the risk of costly workplace accidents.
If you need any help with space planning, our customer service team is here to help. We can advise you on the most suitable racking or shelving type for your needs, put together a floor plan and even arrange a site visit if required.