- The Right System for the Job: Selection depends on how you load (Forklift vs. Hand-picking) and what you store (Pallets vs. Cartons).
- Longspan Shelving: The "Goldilocks" solution—ideal for medium-duty, hand-loaded items like boxes, tools, and retail stock.
- Selective Pallet Racking: The most common system; offers 100% accessibility and suits FIFO (First-In, First-Out) operations.
- High-Density Options: Use Double Deep or Drive-In racking to maximize floor space if you have high volumes of the same SKU.
- Safety Compliance: Ensure all pallet racking meets AS 4084:2023 standards to maintain warehouse safety and WHS compliance.
Warehouse racking optimizes space, streamlines picking, and boosts efficiency for Australian businesses handling palletized goods or manual stock. This guide covers the three main types - industrial shelving like longspan, pallet racking, and specialist systems - with comparisons, benefits, and AS 4084:2023 compliance tips tailored to Sydney warehouses and nationwide operations.
Table of Contents
- 1.0 Comparison Table
- 2.0 Industrial Shelving (Longspan)
- 3.0 Pallet Racking Systems
- 4.0 Specialist Racking
- 5.0 Accessories & Safety
- 6.0 Choosing the Right System
- 7.0 FAQ
1.0 Key Comparison of Racking Types
The key to designing an efficient warehouse is setting up racking systems that optimise the available storage space, while making it easy for people and goods to move around. This usually requires a mix of different types of warehouse shelving.
Warehouse racking systems in Australia are primarily categorized by storage density, accessibility, and the types of goods they are designed to hold. The following table provides a quick comparison of different types of racking, before we go into more detail below.
Longspan offers flexibility that pallet racking lacks for manual operations.
2.0 When Should You Use Industrial Shelving
Industrial shelving is designed on a human scale for manual picking and handling. It can be used by itself in a warehouse installation, or for factory shelving. Alternatively, it is sometimes mixed with pallet racking to support different picking processes and so optimize the efficiency of a given industrial space per square metre.
In summary:
Medium-heavy duty for manual hand-picking of non-palletized items like boxes or parts. Longspan shelving shines here—adjustable steel shelves (120-300kg/level) for warehouses, factories, or garages.
- Longspan: Wide spans (up to 2.5m), easy access, quick install; vs pallet racking, it's forklift-free and reconfigurable.
- Other Types: Rivet (boltless), wire (airflow), mobile, steel.
Explore Falcon's longspan range. Suits mixed picking; pair with pallet racking for hybrid efficiency.
See our blog post on the different types of Industrial Shelving for a more detailed explanation
3.0 Pallet Racking Systems
Pallet racking stores heavy, palletised loads using forklifts. It is ideal for high-volume warehouses.
Loaded pallets can be stored directly on the floor, either singly, one pallet high (floor stacking) or stacked one on top of another (block stacking). This is a useful storage method for some bulky items. However, a high quality pallet racking system is a more efficient and systematic use of the vertical space in a warehouse and so maximise storage density.
Pallet racking systems are one of the most common warehouse storage systems. Essentially, it is a very heavy duty storage system that stores pallets of goods in horizontal rows on multiple levels within a vertical, steel rack. The pallets are typically loaded onto the racks and unloaded with the aid of a forklift.
It is important to ensure that your pallet racking meets Australian Standards such as AS 4084:2023, which sets out the compliance requirements for the design, operation, and maintenance of steel storage racking.
Difference Between Longspan Shelving and Pallet Racking
The fundamental difference between longspan shelving and pallet racking lies in how they are loaded and what they are designed to store. Longspan shelving is built for manual handling, making it an ideal choice for hand-picked items like cartons, tools, and small parts. It is typically lighter and more cost-effective than pallet racking, offering high adjustability and direct access to every shelf.
In contrast, pallet racking is a heavy-duty system designed specifically for palletised goods that require forklifts or mechanical equipment for loading and unloading. While pallet racking provides superior load capacity and maximises vertical space in large warehouses, longspan shelving offers greater flexibility for retail backrooms, workshops, and smaller stockrooms where floor space is limited. Longspan is also easier to add to, when future expansion is required.
Side-by-Side Comparison
| Feature | Longspan Shelving | Pallet Racking |
|---|---|---|
| Handling Method | Manual / Hand-loaded | Forklift / Mechanical |
| Load Capacity | Medium (200–1,000 kg per level) | High (several tonnes per bay) |
| Common Items | Cartons, parts, tools, bulky stock | Large pallets, heavy bulk stock |
| Flexibility | Highly adjustable; easy to reconfigure | Modular but more fixed for stability |
| Cost | More economical for smaller operations | Higher upfront investment |
Three Main Types of Pallet Racking
Pallet racking comes in three sub-types for different densities and access needs.
- Selective Pallet Racking
- Drive-In & Drive Thru Pallet Racking
- Pallet Flow Racking
Choosing the right pallet racking system depends on, amongst other things: the types of items being stored, the SKU mix and how frequently items are picked (FIFO vs LIFO).
3.1 Selective Pallet Racking (static racking)
Selective pallet racking is so called, because you can “select” a pallet without having to move other pallets out of the way. Notably, it is the simplest and cheapest type of pallet racking and it works well with any type of forklift, without the need for specialized material handling equipment. It suits varied SKUs and FIFO inventory.
A static pallet racking system is most commonly 1 pallet deep (single deep). However, you can opt for a two pallet deep configuration (double deep), if you need to store multiple pallets.
3.1.1 Single Deep
Unless specified otherwise, a Selective Pallet Rack generally refers to single deep racking. Single deep selective racking is the most common type of warehouse racking for good reason. It is a very versatile warehouse storage solution; each pallet position can hold a different product or SKU. In addition, each pallet is easily visible and the configuration allows direct access for loading and unloading at any time. So damage during handling is less likely.
It is available in a range of heights and depths and is easy to install and dismantle. Changing the mix of products in the warehouse is simply a matter of swapping out pallets. So it is suitable for both fast and slow moving goods.
Selective pallet rack systems are easy to source and are inexpensive on a cost-per-pallet position basis. A standard forklift with tines is all that is required – no need for special attachments or lift trucks.
It is ideal in situations where there are a large number of different products with low volumes, and different weights and sizes that have a low turnover or are perishable. It is easily configured and works well in warehouse operations that use a First-In, First-Out (FIFO) inventory system. So it suits industries such as manufacturing, retail, food and beverage and pharmaceuticals.
On the downside, it doesn’t provide the same density of storage as other storage options and it requires numerous, wide aisles so that the forklifts can access and maneuver the pallets.
3.1.2 Double Deep Pallet Racking
Double deep or double reach racking shares the same components as single deep racking. The difference is that it’s twice as deep, so each position can accommodate two pallets, one in front of the other. This modification increases the storage capacity of the warehouse space, by reducing the necessary aisle space. However, it does require a special, “double reach” forklift to maneuver the pallets at the back of each position.
A double deep racking system suits situations where there are multiple pallets of the same product stored in-line, back-to-back and where the inventory is managed using a Last-In, First-Out (LIFO) system.
Double deep racking may cost a bit more to implement and may reduce the capacity to efficiently store a wide variety of products. However, the trade off is the increased storage capacity that it offers. It suits applications such as general warehousing and manufacturing, retail and food and beverage warehousing.
In summary
Selective racking allows direct "select" access to every pallet without moving others, suiting varied SKUs and FIFO inventory.
- Single Deep: One pallet deep; versatile for low-turnover, perishable goods like food/pharma. Uses standard forklifts; cost-effective at $ per pallet position.
- Double Deep: Two pallets deep; boosts density by 50% but needs reach trucks for LIFO. Best for uniform stock in retail/manufacturing.
Pros: Flexible, low damage risk. Cons: Wide aisles needed.
3.1.3 Modified Pallet Racking
Modified pallet racking is made from standard pallet racking components, plus some additional modified parts to accommodate odd-shaped (ugly) items. This type of racking is often combined with special material handling vehicles or forklift attachments. Some of the common, modified storage solutions are described in the table below.
| Application | Description |
| Coil/ Drum Racking |
|
| Cable Racking |
|
| Carpet Racking |
|
| Sheet Racking |
|
3.2 Drive-in and Drive-thru Pallet Racking
Drive-in/ Drive-thru racking is a high density storage system. It does away with the horizontal shelves of selective racking and replaces them with ledges on the uprights. The left and right side of each pallet is supported on these ledges and the middle of the pallet is suspended in the air. In this way, the space between the uprights is open, creating a lane that standard-tine forklifts can drive down to deposit a pallet at different heights and depths on the available ledges.
The main advantage of this racking system is that it reduces the aisle space needed for storing stock and so significantly increases the storage capacity of the warehouse over a standard selective racking system.
For best effect, each lane should have low-medium turnover pallets that hold the same SKU’s. Thus it suits situations where there are many pallets of the same product.
These pallet racks come in two variations: drive-in and drive-thru.
3.2.1 Drive-In Racking
Drive-in pallet racking has only one forklift access point at the front. Pallets are loaded and retrieved by a forklift driving into a lane to place or pick up a pallet that is up to 4 spaces deep. The forklift then needs to back out of the lane to maneuver around the warehouse.
This system works best for Last-In, First-Out (LIFO) operations, where the last pallet loaded becomes the most accessible one and so the first one that is subsequently taken out. It suits environments where the inventory turnover isn't high and where the pallets are of uniform size and have relatively uniform loads. As a result, it doesn’t suit products that are perishable, have a short shelf life or are easily damaged.
3.2.2 Drive-Thru Racking
Drive-thru is essentially the same system as Drive-in racking except there is access from both the front and the back of each lane. Forklifts load the new pallets from the front loading aisle and pick or unload the pallets they need from the back.
Because of the different loading and unloading positions, drive-through racking works best with First-In, First-Out (FIFO) storage operations, where many uniform pallets of the same product are stored together. For example: cold storage/ freezer rooms storing meat or flowers, beverage storage and chemical storage. It isn’t ideal for high turnover situations.
In summary
High-density systems where forklifts drive into lanes on ledges, supporting 4-10 pallets deep for same-SKU bulk.
- Drive-In: Front entry only; LIFO for non-perishables like chemicals.
- Drive-Thru: Dual entry; FIFO for cold storage (meat/flowers).
Reduces aisles by 50%, but limits access
3.3 Pallet Flow Racking (gravity flow racking)
A pallet flow rack is a gravity-feed system, where the shelves slope down slightly from the back to the front. Rollers on the shelves allow pallets or cartons that are loaded at the back to roll forward under the effect of gravity. Items are then picked from the front. So it is ideal for a First-in, First-out (FIFO) system that involves perishable or seasonal items
3.3.1 Pallet Flow Racking
Pallet Flow Racking is a high storage density, FIFO storage system, where a standard forklift loads pallets at the back of the racking and picks are unloaded from the front. It is the most expensive form of pallet racking, but it offers efficient high density storage.
The gravity feed system supports very high-density pallet storage of up to 20 pallets deep in one lane. This minimizes the number of aisles needed, while still maintaining efficient inventory turnover. The system enhances the put-away and retrieval process, so reducing the amount of labour required. As a result, it's great where there are limited numbers of high turnover SKU’s in large volumes and where those products have an expiry date.
Pallet flow racks are widely used in perishable-goods warehouses. It works well in freezer warehouses, food distribution centres and grocery warehouses.
Flow racking also comes in a form that works with cartons rather than pallets, which is called Carton Flow Racking.
3.3.2 Carton Flow Racking (Carton Live Storage)
It's possible to use the same gravity-fed strategy with smaller items, such as cartons and containers. Carton flow racks are designed specifically for small, non-palletized, lightweight items that require frequent and rapid picking.
Cartons are loaded at the back of the carton flow rack by hand and then unloaded manually from the front. Carton flow racking is sometimes used above a hand picking area as a buffer storage location that takes advantage of the available airspace.
3.3.3 Push-Back Pallet Racking
Push back racking is a similar gravity-fed system to pallet flow racking, except that the pallets are loaded and unloaded by standard-tine forklifts from the front only. The way it works is pallets are loaded onto an inclined track and cart system that slopes upwards as it goes back, 2-6 pallets deep. When an additional pallet is loaded, it pushes the previous pallet cart(s) upwards and to the back.
Thus the last pallet stored becomes the first in line for picking. So it suits LIFO based inventory systems.
One disadvantage of this system is that the pushing of the pallets creates a higher risk of damage.
Like the other gravity-fed storage systems, it suits the storage of numerous pallets of the same SKU. As a LIFO system, it works better with faster moving products that have a longer shelf life. So it is great for frozen products in cold storage rooms.
In summary
Gravity-fed for FIFO; pallets roll forward on rollers/slopes.
4.0 Specialist Types of Warehouse Racking
There are several specialist types of warehouse racking that are used for special applications and for storing specific, odd-shaped items, as described below.
4.1 Cantilever Racking
Cantilever racks are specifically designed for the storage of long, bulky and awkwardly shaped items. They consist of a series of vertical columns in a line that have horizontal arms on which the long items are stored.
There are two basic types of cantilever racking.
- Single-Sided Cantilever Rack – has horizontal arms on the front side only, so you can position it against a wall
- Double-Sided Cantilever Rack – has horizontal arms on both the front and back, so it requires access aisles on both sides
Cantilever racking makes lengthy materials easy to access. As a result, it is ideal for the storage of items like: lengths of timber, tubing, doors, steel, pipes, and furniture
4.2 Bulk Storage Racks
Bulk storage racks are constructed from robust materials to create a very high load bearing capacity. Specifically, they are designed to accommodate large and very heavy items that don't fit well on traditional shelving. As a result, they are often used for car engines and transmissions, machinery, and other oversized items.
4.3 Tyre Racking
Tyre racking is used to store rimless tyres in a vertical position to minimize warping and distortion (see image below). Tyres can be hand-picked by rolling them out when needed.
Falcon Shelving carries an extensive range of tyre racking and you can see the tyre racking range here.
4.4 A-Frame Racking
A-Frame racking is designed in the shape of a capital letter "A". Long items are simply leaned against the slope of the A-Frame and stored vertically.
Stored items are easy to access and the system maximizes the use of vertical space. As a result, it is great for long hand-picked items like lengths of timber and pipes.
4.5 Mezzanine Floors
A mezzanine floor is a raised storage platform that is used to flexibly increase the available floor space. Mezzanine floors create additional usable floor space without building extensions.
Sometimes the upper and lower mezzanine levels are used for extra shelving that is customized to the needs of the warehouse. At other times the mezzanine is used as: a workspace, a showroom for customers or as an office space.
In summary:
For awkward loads:
- Cantilever: Arms for long items (timber/pipes); single/double-sided.
- Bulk: Oversized heavy goods (engines).
- Tyre Racking: Vertical storage prevents warping; hand-roll access. Falcon tyre racking.
- A-Frame: Leaning long stock.
- Mezzanine: Adds floors for shelving/offices.
5.0 Accessories & Safety
All pallet racking systems in Australia must comply with Australian Standard AS 4084-2023, which covers design, installation, maintenance, and safe operation. Compliance with safety standards is critical to prevent serious safety hazards, potential fines, and legal liabilities in warehouse operations.
Importantly, you can improve the functionality, safety, and efficiency of your warehouse storage system by adding pallet racking accessories like those itemised below:
- Rack guards and frame protectors provide a shield against forklift damage in high traffic areas.
- Safety netting is often installed at the back of racks to help prevent items from falling and causing damage or personal injury.
- Dividers and wire decking help improve space utilization and accessibility. Dividers make it easy to separate different products within the same rack. While wire decking improves airflow, reduces dust buildup, and is required to meet fire code standards in many facilities.
- Clear labeling systems simplify inventory management by making it easy for workers to locate and pick items quickly.
In summary
Enhance your racking with:
- Guards/netting for forklift protection.
- Dividers/wire decking for organization/fire codes.
- Labels for quick picks.
Comply with AS 4084:2023: Inspect annually, load limits posted.
6.0 Choosing the Right Warehouse Storage System
Maximising warehouse efficiency often relies on using a mixture of the different types of warehouse racking and shelving types to accommodate a range of stored items. So it is essential to consider the following factors for choosing the right racking system or shelving:
- Assess stock: Palletized? Use selective/drive. Manual? Longspan.
- Inventory: FIFO? Flow/drive-thru.
- Space: High density? Drive-in.
- Budget: Start selective/longspan.
Contact Falcon for quotes; Sydney pickup or Australia-wide delivery.
7.0 FAQ
What is the difference between warehouse racking and shelving?
The main difference is the loading method. Warehouse racking (like pallet racking) is designed for heavy, palletised loads handled by forklifts. Warehouse shelving (like longspan shelving) is designed for lighter, smaller items that are hand-picked by people at ground level.
What is longspan shelving best used for?
Longspan shelving is the ideal "middle-ground" solution for medium-duty items that are too heavy for standard office shelving but don't require a forklift. It is best used for hand-loaded cartons, automotive parts, workshop tools, and retail stockroom inventory.
Do I need a special forklift for double deep racking?
Yes. Because pallets are stored two-deep, a standard forklift cannot reach the rear position. You will need a reach truck with telescopic forks or a "double-reach" attachment to safely load and retrieve pallets from the back row.
What does AS 4084:2023 compliance mean for my warehouse?
AS 4084:2023 is the Australian Standard for steel storage racking. It sets strict requirements for the design, installation, operation, and maintenance of pallet racking to improve safety, including mandatory annual independent inspections, tighter design tolerances, and enhanced load capacity requirements to handle modern warehousing demands.
Compliance ensures that your pallet racking is designed, installed, and maintained to handle specific load weights safely. It requires regular professional inspections (at least once every 12 months) to ensure the structural integrity of your system.
Which racking system is best for FIFO (First-In, First-Out) inventory?
Selective Pallet Racking and Pallet Flow Racking are the best systems for FIFO. They ensure that the oldest stock is always accessible first, which is critical for perishable goods like food, beverages, or pharmaceuticals.
Can longspan shelving be converted into pallet racking?
No. While they may look similar, longspan shelving lacks the structural load capacity of pallet racking. You should never attempt to store full pallets on longspan shelving, as it creates a significant safety risk and violates Work Health and Safety regulations.
