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How to increase warehouse storage capacity with racking accessories
Why pallet racking often wastes space
You might have plenty of pallet racking, but still not enough storage. Why? Because standard racking doesn’t always match real-life storage needs.
- Unused vertical space: Pallets with varied heights leave large gaps between beam levels.
- Difficult access to deep bays: When pallets at the back are hard to reach, space becomes unusable or requires time-consuming handling.
- Half pallets occupying full spaces: Mixed sizes often force full-pallet spacing even when unnecessary.
- Stock that does not fit standard pallets: Long goods, sheets, reels or drums often occupy more room than they need.
Racking add-ons that support long-term capacity & storage
Accessories allow you to adapt your pallet racking to different stock types and operational needs. Here are the most effective options to increase capacity while improving day-to-day handling.
Pallet racking beams
Beams are the horizontal bars that hold each pallet level. Adjustable beams give you control over beam height and spacing, allowing you to add more pallet levels within the same frame height. Reconfiguring beam positions is one of the easiest ways to increase usable pallet positions without adding new racking.
How racking beams increase capacity:
- Reduces unused vertical gaps
- Allows additional storage levels
- Adapts quickly as stock dimensions change
Pallet rack shelves
How pallet rack shelves increase capacity:
- Enables storage of mixed goods
- Prevents items falling through pallet gaps
- Turns pallet beams into a fully usable shelf surface
This is ideal when storing a mixture of pallets and loose products.
Half pallet inserts
Half pallets are best used when:
- Storing half pallets, quarter pallets or lightweight stock
- Picking frequently from smaller pallet units
- You want to avoid full pallet spacing for half-pallet goods
With correct loading and placement, these inserts significantly increase the number of pallets per aisle.
Pull-out units
How pull-out units boost your storage:
- Keeps aisles narrow while improving access
- Makes rear pallets easy to reach
- Reduces the need for wide forklift turning space
Pull-out units are particularly useful in busy picking areas or where stock rotation is frequent.
Sliding racks / Slide-out racking
How this increases capacity:
- Allows dense, deep storage without compromising access
- Reduces the need for multiple aisles
- Improves picking efficiency in high-volume areas
Sliding racks are ideal for warehouses where floor space is limited but throughput is high.
Dividers and drum cradles
- Dividers help store sheet materials vertically, freeing up floor space.
- Drum cradles allow safe storage of barrels and drums on standard racking.
- Back stops reduce the risk of pallets being pushed off the rear, keeping racking aligned and preventing damage.
- Rack protectors help reduce impact damage, maintaining the structural integrity of your racking over time.
These accessories help keep bays organised, safe and fully utilised.
Consider the weight capacity of your pallet racking
The weight capacity of your pallet racking is one of the most important factors influencing how much you can store. Misunderstanding load ratings often leads to either under-use or unsafe overloading.
Understanding weight limits
Several components affect capacity:
- Beam load capacity: Determines how much weight each pallet level can support.
- Frame (upright) capacity: Determines the total maximum load for the full bay.
- Number of beam levels: More levels can increase storage, but only if frames can support the total weight.
- Load distribution: Unevenly placed loads reduce safe capacity.
How correct capacity increases storage
When beams and frames are correctly matched to your loads, your racking system can:
- Add more pallet levels safely
- Store heavier goods without risk
- Reduce the need for empty or oversized bays
- Extend the life of your racking system
By making sure your racking is built for the loads you store, you prevent costly damage, extend the life of the installation, and maximise your usable space.
Choosing the Right Accessories for Your Warehouse Layout
- Look at the gaps between your beam levels. If you can fit your hand or a whole extra box above most pallets, you likely need to lower your beams or add another level. Adjustable pallet racking beams make this easy.
- If you can’t comfortably reach the back of a shelf, consider adding pull-out units or slide-out racking.
- If you're storing small or half pallets on full-sized levels, switch to half pallet inserts. They let you store two half pallets in one position, immediately increasing capacity.
- Awkwardly shaped items often need dividers, support shelves or drum cradles. These accessories stop items falling, rolling or leaning and make use of space you couldn’t safely fill before.
- If your racking is only set up for pallets, adding shelves or repositioning beams can turn unused gaps into extra picking levels, bulk storage or mixed-use shelves.
A quick walk through your warehouse with these five questions in mind will show you exactly where space is being lost and which accessories will help you reclaim it without expanding your building, moving aisles or buying entirely new racking.
Need help identifying unused storage capacity? Our team can assess your layout and recommend accessories that increase storage without expanding your footprint. Contact us today and unlock the potential of your warehouse!
