Configure Your PalletMax Rack

Step 1 — Select Type of Bay


Step 2 — Configure your Frame


Step 3 — Configure your Beams & Loads


Step 4 — Quantity & Price

Total Rack Load: -

Note: Transport cost and taxes are calculated at checkout.

This product is delivered un-assembled. Unless specified, the installation is under buyer’s scope.
All dimensions mentioned are useable dimensions
Components are labelled for recognition
Designed for easy assembly
All components are powder coated
Delivery in 7–10 working days
Shipped with detailed assembly instructions

Recommended Safety Accessories

Recommended Mandatory Accessories

Before You Begin

Before placing your order, please review the following essential guidelines.

This will help you avoid mistakes, delays, and any confusion during the purchase process.

Please have the following information ready:

  • Accurate measurements of your warehouse or storage area, including any obstacles such as Lighting fixtures, Columns, Switches, HVAC ducts, Sprinkler pipes, Lighting fixtures, Cable trays, or more.
  • Verified floor load capacity (detailed explanation available further below).
  • Type of goods and movement patterns within your storage space.
  • Dimensions and weight of your palletised goods, which determine the required load capacity per level.
  • Rack placement logic: Single-deep racks are intended for wall-mounted placements, while double-deep racks are designed for island aisles.
  • Type of Material Handling Equipment (MHE) you will use, including turning radius, height clearances, and operational space.
  • Confirm if your floor allows drilling and anchoring, since racks need to be anchored to the floor.
  • You will need additional safety accessories to enhance the life of the product.

Once you have these six points ready, you can move on to planning your complete layout. [For a detailed step-by-step guide.]

How to determine the appropriate
rack dimensions for your facility?

  • Wall to Rack Clearance — Maintain a minimum gap of 200mm between the rack and adjacent walls to allow for placement of the pallets with an overhang of 100mm.
  • Side Clearance — Ensure at least 100mm clearance on exposed rack sides.
  • Safety Margins — Allocate a minimum clearance of 200mm around designated handling zones to accommodate safe operations.
  • Determining the Rack Height Needed: A clearance of at least 150 mm must be maintained between the top of the rack and the ceiling. Where goods extend beyond the rack height, ensure a minimum 150 mm clearance between the top of the goods and the ceiling.
  • Structural obstructions: In cases where building columns or pillars are positioned within the storage area, initiate a new run with a main bay. Racks should not be continued around the obstruction, as the residual space created is non-functional and cannot be effectively utilised. Even if you do manage that, the space is not utilisable, hence that rack is useless there.
  • Fire Safety Clearance: Maintain a clearance of 200mm below sprinklers. Ensure racks do not block fire exits or firefighting paths.
  • Aisle Clearance: based on the type of material handling equipment in use:
Material Handling Equipment Clearance Needed
Forklift From 3,500mm to 4,200mm
Reach Truck From 2,700mm to 3,100mm
Stacker From 2,300mm to 2,800mm

Floor Level Tolerance:

  • General flatness: Maximum deviation of 4 mm, measured over any two survey points.
  • Floor slope: Maximum 1 in 500 (≈2 mm per meter).
  • Levelling shims can and should be used during installation to adjust minor unevenness, but the floor should already be reasonably flat before installation.

Floor Load Capacity:

  • Requirement: Floor should withstand at least 5.0 ton/m² (50 kN/m²) for Storix PalletMax racks.
  • Point loads: Each upright leg generally carries 4-5 tonnes, depending on rack height, beam load, and configuration.
  • Concrete grade: Minimum M25 (25 N/mm²) is recommended.
  • Slab thickness: Typically 125–200 mm RCC slab with or without reinforcement mesh, designed considering rack loads plus forklift traffic or any other material handling
    equipment (MHE) used.

The Complete PalletMax Rack

A complete pallet rack main bay is made up of at least two upright frames and four load beams. Additional bays can be attached using two beams, which are suspended between the upright frames. These beams are secured with locking pins to prevent accidental dislodging. The upright frames are reinforced with diagonal and horizontal braces made of galvanised C-profiles. For extra stability, the load beams can be connected using depth bars, and the length of the beams defines the bay length.

Because of their high load capacity, pallet racks must always be anchored to the warehouse floor using special floor anchors. Anchoring prevents racks from tipping over and ensures that their original alignment is maintained. In large installations, racks are exposed to continuous forces from frequent loading and unloading operations, which can cause gradual movement over time. By securing the racks with floor anchors, this movement is eliminated, and the system remains firmly in place.

01

Frame — Vertical structure that supports beams
and holds the racking system. It is made with
vertical components called uprights.

02

Horizontal & Diagonal Bracing — Provides lateral
stability to prevent racking from swaying, and
connects the 2 uprights together.

03
  1. Load Beam — Horizontal component that supports
    the load (i.e. pallets).
  2. Lock Pin — Secures beams to the frame
    to prevent dislodging.
05

Aisle Identification Board — Labels aisles
for easy identification and organisation.

06

Rack Load Notice — Displays the load capacity
of the racking system to ensure safe usage.

07

Upright Guard — Protects each upright from
damage due to forklifts or other
equipment. It is of 2 types
U-shaped & L-shaped,
both of these serve the same
purpose but have different considerations.

08

Frame Guard — Protects each frame from
damage due to forklifts or other
equipment.
It is of 2 types U-shaped & L-shaped,
both of these serve the same
purpose but have different considerations.

09

Row Spacer — Maintains distance
between racks, ensuring stability.

10

Top Tie Beam — Connects frames at the top,
adding stability and preventing flexing.

11

Wall Connector — It is a metal
component used to anchor or
connect the racking
structure to a nearby wall
for extra stability and safety

12

Welded Pallet Support Bar
— It is a safety and load support accessory
that supports
pallets across the beam.

13

Z Type Pallet Support Bar
— It is a safety and load support accessory
that supports pallets across the beam.
It also acts a guide while placing
pallets to avoid any
incidents.

14

Panel Type Pallet Support Bar
—It is a safety and load support
accessory that supports pallets across the beam.

15

Welded Panel Support Bar
— It is a safety and panel
support accessory that supports
various decks across the beam.

16

Pallet Stopper
— Prevents items from falling
off the back of the rack.

17

Levelling Shims
— Corrects any unevenness in the floor,
ensuring the rack is level.
The upright leg is placed on the shim.

18

Upright Leg — or a Footplate. This is where the upright rests upon.
The leg is
anchored into the
floor to ensure sturdiness.

19

Panel
— Panels are placed on the beams
that provide acontinuous surface for irregular
shaped items, loose items, or different /odd shaped pallets.

01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
01. Frame

Frame — Vertical structure that supports beams and holds the racking system. It is made with vertical components called uprights.

Horizontal & Diagonal Bracing — Provides lateral
stability to prevent racking from swaying, and
connects the 2 uprights together.

  1. Load Beam — Horizontal component that supports
    the load (i.e. pallets).
  2. Lock Pin — Secures beams to the frame
    to prevent dislodging.

Aisle Identification Board — Labels aisles
for easy identification and organisation.

Rack Load Notice — Displays the load capacity of the racking system to ensure safe usage.

Upright Guard — Protects each upright from damage due to forklifts or other equipment. It is of 2 types U-shaped & L-shaped, both of these serve the same purpose but have different considerations.

Frame Guard — Protects each frame from damage due to forklifts or other equipment. It is of 2 types U-shaped & L-shaped, both of these serve the same purpose but have different considerations.

Row Spacer — Maintains distance between racks, ensuring stability.

Top Tie Beam — Connects frames at the top, adding stability and preventing flexing.

Wall Connector — It is a metal component used to anchor or connect the racking structure to a nearby wall for extra stability and safety

Welded Pallet Support Bar — It is a safety and load support accessory that supports pallets across the beam.

Z Type Pallet Support Bar
— It is a safety and load support accessory that supports pallets across the beam. It also acts a guide while placing pallets to avoid any incidents.

Panel Type Pallet Support Bar —It is a safety and load support accessory that supports pallets across the beam.

Welded Panel Support Bar — It is a safety and panel support accessory that supports various decks across the beam.

Pallet Stopper — Prevents items from falling off the back of the rack.

Levelling Shims — Corrects any unevenness in the floor, ensuring the rack is level. The upright leg is placed on the shim.

Upright Leg — or a Footplate. This is where the upright rests upon. The leg is anchored into the floor to ensure sturdiness.

The Main Bay & the Add-on Bay

The Main Bay:

Often referred to as the Starter Bay, this unit is a complete rack section made up of two upright frames connected by a full set of beams. It can function independently as a single unit or serve as the starting point for a continuous row of racks. From the Main Bay, the system can be extended as needed, with the help of various compatible accessories and components.

The Add-on Bay:

Commonly known as the Extension Bay, this unit consists of one upright frame and a set of beams. Unlike the Main Bay, it cannot stand alone or be used as the first unit in a run. Instead, it is designed to connect directly to a Main Bay, forming a seamless extension. While the depth of the Add-on Bay must match that of the Main Bay, its height and length may be adjusted to suit specific requirements.

About Frames & Beams

Frames:

The Frame Depth of the PalletMax Rack has 2 variants — Depth of 800mm and 1000mm.

A Frame with 1000mm Depth is widely used since it easily accommodates Euro pallet storage.

A lateral storage of pallets is possible, but only with the help of Pallet Support Bars, or 4B Panels with Welded Panel Support Bars.

  • We do not recommend storing pallets on frames with an overhang of 150mm or more
    on either side.
  • When the pallet has an overhang of about 100 mm on each side, pallet support bars
    are not strictly required, though they may still be used if you wish to — any type of
    pallet support bar can be used in this case.
  • For pallets with the same depth as the rack, a Z-Type Pallet Support Bar or a Panel-Type
    Pallet Support Bar should be used.
  • For pallets with a depth smaller than the rack, a Welded Pallet Support Bar must be
    used.

The Frames of the PalletMax Rack have 7 heights — 3m, 3.5m, 4m, 4.5m, 5m, 5.5m, 6m. The number of levels you can have depends on 2 factors: load per level, & the height of the frame. Check the table to see how many levels will fit your needs:

The number of levels in a rack can be maximised as long as the Total Rack Load remains within the bay’s capacity.

  • Our racks are designed to carry up to 9,000 kgs per bay, with each level capable of supporting a maximum of 2,000 kgs.

Beams:

The PalletMax Rack is designed to have 3 different Rack Lengths — 1900mm, 2300mm, & 2700mm.

The maximum level-to-level height is 1500mm. Increasing this any further will decrease the load carrying capacity, substantially. At the same time, decreasing level-to-level height will briefly increase the load carrying capacity – although this is strongly not recommended by us. If you still wish to add more levels, you can always purchase extra beams by clicking here.

  • Note: Always ensure that the highest level is positioned at least 500mm below the top edge of the upright frame. This safety clearance prevents stored goods from slipping sideways over the top of the rack. It is mandatory for all racks that are facing aisles or exposed to traffic routes — where movement and people are present. It is not required for racks positioned back-to-back within a continuous row since no people are present and goods cannot fall sideways to the next frame.

Failure to observe this rule may result in falling goods and increased risk of accidents.

Regardless of the rack length or load-per-level combination selected, it is essential to ensure proper load distribution along the beam.

  • We recommend maintaining a clearance of 100 mm at the rack corners for pallet positioning, along with a 100 mm gap between the pallets. In cases where pallet dimensions allow for three pallets per level, the palletto-pallet gap may be adjusted to 80 mm. The reference table below provides guidance on how many pallets can be accommodated for each rack length.

For different loads per level, we have different profiles of beams available. These profiles change as per thickness and dimensions.

Number of Levels Possible Height Wise Table
Frame Height 2 Levels 3 Levels 4 Levels 5 Levels
3,000mm Yes Yes
3,500mm Yes Yes Yes
4,000mm Yes Yes Yes
4,500mm Yes Yes
5,000mm Yes Yes Yes
5,500mm Yes Yes Yes
6,000mm Yes Yes Yes

Frequently Asked Questions

What Can be Stored?

Palletised materials are stored horizontally across multiple levels, with compatible material handling equipments: Forklifts, Reach Trucks, Stackers, Stacker Cranes, etc. which are used to load and unload pallets onto the racks. Perfect for products/ inventory with multiple SKU’s, inventory/ goods with FIFO (First-In, First-Out) movement, medium-heavy weighted goods/ inventory. It gives direct access to each pallet without disturbing/ having to move others.

Your order will take at least 6 days to process plus the additional time taken for delivery shown at your checkout when it is finalised. In many cases, the processing time can
change too.

For Heights upto 3,500mm you will need a team of 4-7 people, for heights upto 6,000mm you will need a team of 7-9 people. 1 Main Bay usually takes 1hour depending on the skillset and tools used.
Because main bays or starters are the only units that can stand alone, you will need one for every run and one for every standalone unit in your warehouse layout. This makes calculating the number of starters you need simple. Determine how many runs and standalone units you need — that’s the number of starters you should purchase.

Add-ons are for continuous runs, and these calculations require more thought. Consult your layout to determine how many continuous runs you need to outfit. Then, record the number of bays each run will have. If your warehouse has 10 runs with 14 bays per run, you’ll need 13 add-ons for each run. Multiplying 13 add-on bays for each run by 10 runs is a total of 130 add-on bays.

While ordering a basic Main Bay, you will get all the required main components in your order — 4 uprights, its necessary quantity of horizontal and diagonal bracings, 4 upright legs, 4 levelling shims, 2 load beams for each level, & 4 lock pins for each level. All the necessary hardwares and fasteners are also provided in the required quantities to anchor and secure the mentioned components.

While ordering a basic Add-on Bay, you will receive — 2 uprights, its necessary quantities of horizontal and diagonal bracings, 2 upright legs, 2 levelling shims, 2 load beams for each level, & 4 lock pins for each level. All the necessary hardwares and fasteners are also provided in the required quantities to anchor and secure the mentioned components.

Along with these main components, any other accessory or extra component added in your order will also be sent with its required fasteners.

No tools will be provided and we may provide extra fasteners in our kits.

Of course, all the assembly instructions and user manuals are also provided. A digital
copy of the same will be available for you in your account as a backup too.

Absolutely. We know that choosing the right rack system can feel overwhelming. You can explore our support and design services here to get step-by-step assistance.

Our support team is available Monday to Friday, 9:00 AM to 5:00 PM (IST). You can reach us at [email], and we’ll get back to you promptly.

Once a product has been shipped, cancellations and returns are not accepted. For full details, please review our policies here.

Our Promise

At Storix, we prioritise earning our customers’ trust through superior design, quality, and safety in every aspect of our PMR systems. Our solutions incorporate carefully designed components, that ensure efficient storage and ease of use. We follow the highest design standards to maximise space utilisation while prioritising operator safety, creating systems that are both reliable & user-friendly, and also safe for the environment.

Installation is seamless and hassle-free, allowing customers to experience immediate benefits without unnecessary delays. Our premium quality lead-free powder coating enhances durability, ensuring a longer product life while maintaining exceptional performance under rigorous conditions. With Storix, customers can trust in a system that delivers unmatched reliability, safety, and convenience.

More About Pallet Racking

Consider Storix PalletMax Rack for its most superior and conventional design offering seamless accessibility, robust durability, and efficient storage for diverse inventory needs.

  1. Adaptability: easily adapts to different product sizes, weights, and specifications, making it suitable for a wide range of industries. Organise and retrieve goods quickly, boosting productivity across your warehouse.
  2. Accessibility: Every pallet is easily and directly accessible without the need to move others, ensuring precise stock control and seamless inventory management.
  3. Optimal Stock Flow: Simplifies tracking, retrieval, and management of stored goods.
  4. Easily Modifiable: Its modular design allows for quick installation, expansion, or part replacement without disruptions. You can easily scale your storage effortlessly as your business grows or inventory changes.
  5. Versatility: Perfect for businesses requiring FIFO (First-In, First-Out) inventory management, ensuring goods move efficiently.
  6. Excellant ROI.


If Your Products…

  1. Require frequent or continuous loading and unloading. For example: clothing, electronics, toys, spare parts, groceries, etc.
  2. Need individual pallet accessibility with a variety of SKU’s. For example: medicines & drug variants, packaged items like food or beverages, etc.
  3. Have a high turnover and require FIFO (First In-First Out) management. For example: expiry sensitive items like food or medicines, seasonal cosmetics or clothes, fresh produces, etc.
  4. Demand flexible storage for varying product sizes and quick retrieval for fast order fulfilment. For example: a range of small to large electronic appliances, building materials like cement bags or tools of various sizes, car parts, small automotive accessories to large engine components, etc.
  5. Are heavy or bulky, requiring optimal use of vertical space with easy access for picking and organised stocking. For example: tires, car batteries, medium weight tools, etc.
  6. Are sensitive or time bound, requiring efficient stock control. For example: vaccines, perishable items, high demand products, etc.
  7. Are fragile yet medium to heavy in weight. For example: glass bottles, fragile containers, delicate items, medium weighted furniture, etc.
  8. Require a durable and versatile storage solution. For example: medium weighted machine parts, bricks, tiles, etc.

Different Methods of Storage & Retrieval on Pallet Racks:

  • FIFO — First In, First Out
    • Meaning: The first pallet stored is the first one retrieved.
    • Where is it Used: Essential for perishable goods, pharmaceuticals, food and beverages, or anything with an expiry date.
    • Types of Racking Systems: Drive-through racks, pallet flow racks (gravity flow), pushback (when designed accordingly).
    • Benefits: Ensures older stock is cleared first, minimising obsolescence or spoilage.
  • LIFO — Last In, First Out
    • Meaning: The most recently stored pallet is the first one retrieved.
    • Where is it Used: Common in non-perishable goods, bulk storage, and when space utilisation is more important than rotation.
    • Racking Systems: Drive-in racks, push-back racks.
    • Benefit: Maximises density in limited warehouse space.
  • Random Access — Selective Storage
    • Meaning: Any pallet can be accessed at any time, regardless of when it was stored.
    • Where is it Used: General warehouses, distribution centers, e-commerce, mixed SKU
      storage.
    • Racking Systems: Selective pallet racking (the most common type).
    • Benefit: High accessibility, simple operation, flexibility for varied products.
  • Batch Storage — Block or Bulk Storage
    • Meaning: Pallets of the same SKU are grouped together in blocks, often stacked or
      stored in deep-lane systems.
    • Where is it Used: Warehouses handling fewer SKUs but in larger volumes.
    • Racking Systems: Drive-in racks, double-deep racks.
    • Benefit: Efficient for bulk handling and maximising storage density.
  • Dynamic/ Flow Storage
    • Meaning: Uses gravity rollers or conveyors so pallets automatically flow from loading
      side to picking side. Usually FIFO.
    • Where is it Used: High-volume distribution centers, cold storage, high-velocity SKUs.
    • Racking Systems: Pallet flow racks, carton flow racks.
    • Benefit: Automatic stock rotation, reduced handling, faster picking.
  • Sequential — Zone or Wave Picking
    • Meaning: Goods are stored and retrieved in a planned sequence, sometimes combining FIFO/LIFO with order-picking logic.
    • Where is it Used: Automated warehouses, AS/RS systems.
    • Racking Systems: Mobile racking, shuttle systems, ASRS (Automated Storage and Retrieval Systems).
    • Benefit: High efficiency in order fulfilment, integrates with WMS (Warehouse Management Systems).

How to determine the appropriate
rack dimensions for your facility?

  • Wall to Rack Clearance — Maintain a minimum gap of 200mm between the rack and adjacent walls to allow for placement of the pallets with an overhang of 100mm.
  • Aisle Clearance — Aisle spaces should be in accordance with the specifications of the material handling equipment in operation.
  • Side Clearance — Ensure at least 100mm clearance on exposed rack sides.
  • Safety Margins — Allocate a minimum clearance of 200mm around designated handling zones to accommodate safe operations.
  • Determining the Rack Height Needed: A clearance of at least 150 mm must be maintained between the top of the rack and the ceiling. Where goods extend beyond the rack height, ensure a minimum 150 mm clearance between the top of the goods and the ceiling.
  • Structural obstructions: In cases where building columns or pillars are positioned within the storage area, initiate a new run with a main bay. Racks should not be continued around the obstruction, as the residual space created is non-functional and cannot be effectively utilised. Even if you do manage that, the space is not utilisable, hence that rack is useless there.
Material Handling Equipment Clearance Needed
Forklift From 3,500mm to 4,200mm
Reach Truck From 2,700mm to 3,100mm
Stacker From 2,300mm to 2,800mm

Floor Clearances Needed

Floor Level Tolerance:

  • General flatness: Maximum deviation of 4 mm, measured over any two survey points.
  • Floor slope: Maximum 1 in 500 (≈2 mm per meter).
  • Levelling shims can and should be used during installation to adjust minor unevenness,  but the floor should already be reasonably flat before installation.

Floor Load Capacity:

  • Requirement: Floor should withstand at least 5.0 ton/m² (50 kN/m²) for Storix PalletMax racks.
  • Point loads: Each upright leg generally carries 4-5 tonnes, depending on rack height, beam load, and configuration.
  • Concrete grade: Minimum M25 (25 N/mm²) is recommended.
  • Slab thickness: Typically 125–200 mm RCC slab with or without reinforcement mesh, designed considering rack loads plus forklift traffic or any other material handling equipment (MHE) used.

The Main Bay & the Add-on Bay

The Main Bay:

Often referred to as the Starter Bay, this unit is a complete rack section made up of two upright frames connected by a full set of beams. It can function independently as a single unit or serve as the starting point for a continuous row of racks. From the Main Bay, the system can be extended as needed, with the help of various compatible accessories and components.

The Add-on Bay:

Commonly known as the Extension Bay, this unit consists of one upright frame and a set  of beams. Unlike the Main Bay, it cannot stand alone or be used as the first unit in a run.  Instead, it is designed to connect directly to a Main Bay, forming a seamless extension.  While the depth of the Add-on Bay must match that of the Main Bay, its height and length  may be adjusted to suit specific requirements.

Calculating How Many Bays Do I Need?

Main Bay

Because main bays are the only units that can stand alone, you will need one for every run. To determine the total number of main bays that can be accommodated, first review the layout to confirm the overall storage depth available, accounting for the required clearances on all sides. Next, finalise the rack depth to be used.

 

If there are pillars or columns in the facility, the rack run should stop before the pillar with the required clearances. After the pillar, the run can continue by starting again with a Main Bay, keeping the same spacing in mind.

An example, if the available storage depth is 18,000 mm (18 m) and the selected rack depth is 800 mm, we must also consider the clearance required for the Material Handling Equipment (MHE). Assuming a forklift is in use, an aisle width of 3,200 mm is required between two rack runs.
Each rack run requires 800 mm (rack depth) + 3,200 mm (aisle clearance), except at the outermost racks, which only require the rack depth without additional clearance behind them.

For 5 rack runs (main bays):



  • Total rack depth = 5 × 800 mm = 4,000 mm

  • Total aisle space = 4 × 3,200 mm = 12,800 mm

  • Combined depth requirement = 16,800 mm, which fits within the available 18,000 mm.

Adding a 6th rack run (main bay) would require an additional 3,200 mm (aisle) + 800 mm (rack depth) = 4,000 mm, increasing the total depth to 20,800 mm, which exceeds the available storage depth.

 

Add-on Bays:


When planning for add-on bays in a continuous run, the calculation differs slightly from main bays and requires careful evaluation of the available layout. Begin by confirming the total length of the area available for racking (accounting for the required clearances), and then finalize the rack length.

 

For example, if the available floor length is 25,000 mm (25 m) and the chosen rack length is 2,300 mm, the first unit will be a Main Bay, which occupies one rack length. This leaves a residual space of: 25,000 mm – 2,300 mm = 22,700 mm Within this remaining space, only add-on bays can be placed.

 

With 9 add-on bays:


Total length = 9 × 2,300 mm = 20,700 mm, which fits within the available 22,700 mm.

 

With10 add-on bays:


Total length = 10 × 2,300 mm = 23,000 mm, which exceeds the available space.

Therefore, the maximum configurations for this layout is 1 main bay + 9 add-on bays, making a total of 10 bays in the run.

The Complete PalletMax Rack

A complete pallet rack main bay is made up of at least two upright frames and four load beams. Additional bays can be attached using two beams, which are suspended between the upright frames. These beams are secured with locking pins to prevent accidental dislodging. The upright frames are reinforced with diagonal and horizontal braces made of galvanised C-profiles. For extra stability, the load beams can be connected using depth bars, and the length of the beams defines the bay length.

Because of their high load capacity, pallet racks must always be anchored to the warehouse floor using special floor anchors. Anchoring prevents racks from tipping over and ensures that their original alignment is maintained. In large installations, racks are exposed to continuous forces from frequent loading and unloading operations, which can cause gradual movement over time. By securing the racks with floor anchors, this movement is eliminated, and the system remains firmly in place.

  1. Frame — Vertical structure that supports beams and holds the racking system. It is made with vertical components called uprights.
  2. Horizontal & Diagonal Bracing — Provides lateral stability to prevent racking from swaying, and connects the 2 uprights together.
  3. Load Beam — Horizontal component that supports the load (i.e. pallets).
  4. Lock Pin — Secures beams to the frame to prevent dislodging.
  5. Aisle Identification Board — Labels aisles for easy identification and organisation.
  6. Rack Load Notice — Displays the load capacity of the racking system to ensure safe usage.
  7. Upright Guard — Protects each upright from damage due to forklifts or other equipment. It is of 2 types — U-shaped & L-shaped, both of these serve the same purpose but have different considerations.
  8. Frame Guard — Protects each frame from damage due to forklifts or other equipment. It is of 2 types — U-shaped & L-shaped, both of these serve the same purpose but have different considerations.
  9. Row Spacer — Maintains distance between racks, ensuring stability.
  10. Top Tie Beam — Connects frames at the top, adding stability and preventing flexing.
  11. Wall Connector — It is a metal component used to anchor or connect the racking structure to a nearby wall for extra stability and safety
  12. Welded Pallet Support Bar — It is a safety and load support accessory that supports pallets across the beam.
  13. Z Type Pallet Support Bar — It is a safety and load support accessory that supports pallets across the beam. It also acts a guide while placing pallets to avoid any incidents.
  14. Panel Type Pallet Support Bar — It is a safety and load support accessory that supports pallets across the beam.
  15. Welded Panel Support Bar — It is a safety and panel support accessory that supports various decks across the beam.
  16. Pallet Stopper — Prevents items from falling off the back of the rack.
  17. Levelling Shims — Corrects any unevenness in the floor, ensuring the rack is level. The upright leg is placed on the shim.
  18. Upright Leg — or a Footplate. This is where the upright rests upon. The leg is anchored into the floor to ensure sturdiness.
  19. Panel — Panels are placed on the beams that provide a continuous surface for irregular shaped items, loose items, or different /odd shaped pallets.

About Frames & Beams

Frames:

The Frame Depth of the PalletMax Rack has 2 variants — Depth of 800mm and 1000mm.

A Frame with 1000mm Depth is widely used since it easily accommodates euro pallets storage.

A lateral storage of pallets is possible, but only with the help of Pallet Support Bars, or 4B Panels with Welded Panel Support Bars.

  • We do not recommend storing pallets on frames with an overhang of 150mm or more on either side.
  • When the pallet has an overhang of about 100 mm on each side, pallet support bars are not strictly required, though they may still be used if you wish to — any type of
    pallet support bar can be used in this case.
  • For pallets with the same depth as the rack, a Z-Type Pallet Support Bar or a Panel-Type Pallet Support Bar should be used.
  • For pallets with a depth smaller than the rack, a Welded Pallet Support Bar must be used.

The Frames of the PalletMax Rack have 7 heights — 3m, 3.5m, 4m, 4.5m, 5m, 5.5m, 6m. The number of levels you can have depends on 2 factors: load per level, & the height of the frame. Check the table to see how many levels will fit your needs:

Number of Levels Possible Height Wise Table
Frame Height 2 Levels 3 Levels 4 Levels 5 Levels
3,000mm Yes Yes – 
3,500mm Yes Yes Yes 
4,000mm Yes Yes Yes 
4,500mm – Yes Yes 
5,000mm – Yes Yes Yes
5,5000mm – Yes Yes Yes
6,000mm – Yes Yes Yes

The number of levels in a rack can be maximised as long as the Total Rack Load remains  within the bay’s capacity. Our racks are designed to carry up to 9,000 kgs per bay, with  each level capable of supporting a maximum of 2,000 kgs.  

Beams:

The PalletMax Rack is designed to have 3 different Rack Lengths — 1900mm, 2300mm, &  2700mm.  

The maximum level-to-level height is 1500mm. Increasing this any further will decrease  the load carrying capacity, substantially. At the same time, decreasing level-to-level height  will briefly increase the load carrying capacity – although this is strongly not  recommended by us. If you still wish to add more levels, you can always purchase extra  beams by clicking here.  

Note: Always ensure that the highest level is positioned at least 500mm below the top  edge of the upright frame. This safety clearance prevents stored goods from slipping  sideways over the top of the rack. It is mandatory for all racks that are facing aisles or  exposed to traffic routes — where movement and people are present. It is not required  for racks positioned back-to-back within a continuous row since no people are present  and goods cannot fall sideways to the next frame.  

Failure to observe this rule may result in falling goods and increased risk of accidents.  

Regardless of the rack length or load-per-level combination selected, it is essential to  ensure proper load distribution along the beam. We recommend maintaining a clearance  of 100 mm at the rack corners for pallet positioning, along with a 100 mm gap between  the pallets. In cases where pallet dimensions allow for three pallets per level, the pallet to-pallet gap may be adjusted to 80 mm. The reference table below provides guidance  on how many pallets can be accommodated for each rack length.  

For different loads per level, we have different profiles of beams available. These profiles  change as per thickness and dimensions.  

Beams — Length wise No. Of Pallets Distribution
Pallet Size  Rack Length = 1900mm  Rack Length = 2300mm  Rack Length = 2700mm
800L x 1000D  2 Pallets per Level  2 Pallets per Level  2 Pallets per Level
800L x 1200D  2 Pallets per Level  2 Pallets per Level  2 Pallets per Level
1000L x 1000D  –  2 Pallets per Level  2 Pallets per Level
1000L x 1200D  –  2 Pallets per Level  2 Pallets per Level
1200L x 1000D  –  –  2 Pallets per Level
1200L x 1200D  –  –  2 Pallets per Level

Pre-Installation Notes

Warning:

Outdoor installation is not recommended unless the racking system is specifically engineered for outdoor use. Outdoor environments require calculations for wind load, snow load, temperature variations, and weather impact, none of which are accounted for in standard rack designs.
These racks are not suitable for cold storage applications.
Jay Storix Racks are designed to operate safely within a temperature range of 0°C to 50°C.

Team Size Planning:
To ensure safe and efficient installation, the following team sizes are recommended (for an area of about 5,000 sq.ft.):
– Rack height up to 2,500 mm: 6–8 installers
– Rack height up to 3,500 mm: 8–10 installers
– Rack height up to 6,000 mm: 10–12 installers

Tools Needed for Assembly:
Drilling & Fastening Tools:
  • – Hammer Drill (10 mm bit diameter) — for drilling anchor holes in the concrete floor
  • – Torque Wrenches (10 mm, 13 mm, 16 mm) — for tightening hex bolts to specified torque values
Measuring & Aligning Tools
  • – Measuring Tape — precise distance measurement
  • – Spirit Level / Laser Level — for ensuring horizontal alignment
  • – Plumb Line / Laser Level — for vertical alignment of uprights and frames
  • – Chalk Line / Floor Marker — for marking reference lines
  • – Chalk / Marker — for marking upright positions and drilling points
Assembly Tools:
  • – Rubber Mallet — for securing beams without damaging components
  • – Hammer — for anchoring frames to the floor
  • – Nails — for temporarily fixing chalk lines
  • – Elevated Flat Tables / Boxes — for frame assembly at ergonomic height
Material Handling & Access Equipment:
  • – Forklift & Rope — for moving and positioning assembled frames
  • – Man-Lift (or ladder) — for working at elevated heights

Recommended Safety Gear - PPE:

Safety helmet

High-visibility vest

Steel-toe safety shoes

Abrasion-resistant work gloves

Safety goggles

Hearing protection

Body harnesses and double-tied lanyards

Assembly of the Racks at Site:
The detailed instructions for actual installation will be provided to you in your kit. The installation manual will have diagrams to ease the understanding.

Floor & Site Clearance:

Floor level accuracy: Inspect the warehouse floor for unevenness
– Floor slope: up to 2 mm per meter.
– Floor flatness: max 4 mm deviation between any two survey points.

Load-bearing capacity: Confirm the floor can support the racking system
– Minimum requirement: 5 ton/m². Each upright leg typically carries 4–5 tonnes.
– Ensure both dead load and live load are considered.

Floor type and specs: Concrete floors are preferred for anchoring due to strength and stability.
– Confirm ceiling height, floor area, and overhead obstructions.
– Minimum concrete grade: M25 (25 N/mm²) with 125–200 mm RCC slab thickness.

The Complete PalletMax Rack

01

Frame — Vertical structure that supports beams
and holds the racking system. It is made with
vertical components called uprights.

02

Horizontal & Diagonal Bracing — Provides lateral
stability to prevent racking from swaying, and
connects the 2 uprights together.

03
  1. Load Beam — Horizontal component that supports
    the load (i.e. pallets).
  2. Lock Pin — Secures beams to the frame
    to prevent dislodging.
05

Aisle Identification Board — Labels aisles
for easy identification and organisation.

06

Rack Load Notice — Displays the load capacity
of the racking system to ensure safe usage.

07

Upright Guard — Protects each upright from
damage due to forklifts or other
equipment. It is of 2 types
U-shaped & L-shaped,
both of these serve the same
purpose but have different considerations.

08

Frame Guard — Protects each frame from
damage due to forklifts or other
equipment.
It is of 2 types U-shaped & L-shaped,
both of these serve the same
purpose but have different considerations.

09

Row Spacer — Maintains distance
between racks, ensuring stability.

10

Top Tie Beam — Connects frames at the top,
adding stability and preventing flexing.

11

Wall Connector — It is a metal
component used to anchor or
connect the racking
structure to a nearby wall
for extra stability and safety

12

Welded Pallet Support Bar
— It is a safety and load support accessory
that supports
pallets across the beam.

13

Z Type Pallet Support Bar
— It is a safety and load support accessory
that supports pallets across the beam.
It also acts a guide while placing
pallets to avoid any
incidents.

14

Panel Type Pallet Support Bar
—It is a safety and load support
accessory that supports pallets across the beam.

15

Welded Panel Support Bar
— It is a safety and panel
support accessory that supports
various decks across the beam.

16

Pallet Stopper
— Prevents items from falling
off the back of the rack.

17

Levelling Shims
— Corrects any unevenness in the floor,
ensuring the rack is level.
The upright leg is placed on the shim.

18

Upright Leg — or a Footplate. This is where the upright rests upon.
The leg is
anchored into the
floor to ensure sturdiness.

19

Panel
— Panels are placed on the beams
that provide acontinuous surface for irregular
shaped items, loose items, or different /odd shaped pallets.

01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
01. Frame

Frame — Vertical structure that supports beams and holds the racking system. It is made with vertical components called uprights.

Horizontal & Diagonal Bracing — Provides lateral
stability to prevent racking from swaying, and
connects the 2 uprights together.

  1. Load Beam — Horizontal component that supports
    the load (i.e. pallets).
  2. Lock Pin — Secures beams to the frame
    to prevent dislodging.

Aisle Identification Board — Labels aisles
for easy identification and organisation.

Rack Load Notice — Displays the load capacity of the racking system to ensure safe usage.

Upright Guard — Protects each upright from damage due to forklifts or other equipment. It is of 2 types U-shaped & L-shaped, both of these serve the same purpose but have different considerations.

Frame Guard — Protects each frame from damage due to forklifts or other equipment. It is of 2 types U-shaped & L-shaped, both of these serve the same purpose but have different considerations.

Row Spacer — Maintains distance between racks, ensuring stability.

Top Tie Beam — Connects frames at the top, adding stability and preventing flexing.

Wall Connector — It is a metal component used to anchor or connect the racking structure to a nearby wall for extra stability and safety

Welded Pallet Support Bar — It is a safety and load support accessory that supports pallets across the beam.

Z Type Pallet Support Bar
— It is a safety and load support accessory that supports pallets across the beam. It also acts a guide while placing pallets to avoid any incidents.

Panel Type Pallet Support Bar —It is a safety and load support accessory that supports pallets across the beam.

Welded Panel Support Bar — It is a safety and panel support accessory that supports various decks across the beam.

Pallet Stopper — Prevents items from falling off the back of the rack.

Levelling Shims — Corrects any unevenness in the floor, ensuring the rack is level. The upright leg is placed on the shim.

Upright Leg — or a Footplate. This is where the upright rests upon. The leg is anchored into the floor to ensure sturdiness.

Material Handling Equipment Clearance Needed
Forklift From 3,500mm to 4,200mm
Reach Truck From 2,700mm to 3,100mm
Stacker From 2,300mm to 2,800mm

Bays

The Main Bay:

Often referred to as the Starter Bay, this unit is a complete rack section made up of two upright frames connected by a full set of beams. It can function independently as a single unit or serve as the starting point for a continuous row of racks. From the Main Bay, the system can be extended as needed, with the help of various compatible accessories and components.

The Add-on Bay:

Commonly known as the Extension Bay, this unit consists of one upright frame and a set of beams. Unlike the Main Bay, it cannot stand alone or be used as the first unit in a run. Instead, it is designed to connect directly to a Main Bay, forming a seamless extension. While the depth of the Add-on Bay must match that of the Main Bay, its height and length may be adjusted to suit specific requirements.

Frames:

The Frame Depth of the PalletMax Rack has 2 variants — Depth of 800mm and 1000mm.

  • We do not recommend storing pallets on frames with an overhang of 150mm or more on either side.

Jay Storix Frames have 7 heights — 3m, 3.5m, 4m, 4.5m, 5m, 5.5m, 6m. The number of levels you can have depends on 2 factors: load per level, & the height of the frame. Check the table to see how many levels will fit your needs.

The number of levels in a rack can be maximised as long as the Total Rack Load remains within the bay’s capacity. Our racks are designed to carry up to 9,000 kgs per bay, with each level capable of supporting a maximum of 2,000 kgs.

Beams:

The PalletMax Rack is designed to have 6 different Rack Lengths — 1000mm, 1200mm, 1400mm, 1900mm, 2300mm, & 2700mm.

The maximum level-to-level height is 1500mm. Increasing this any further will decrease the load carrying capacity, substantially. At the same time, decreasing level-to-level height will briefly increase the load carrying capacity – although this is strongly not recommended by Jay Storix.

Regardless of the rack length or load-per-level combination selected, it is essential to ensure proper load distribution along the beam. We recommend maintaining a clearance of 100 mm at the rack corners for pallet positioning, along with a 100 mm gap between the pallets. In cases where pallet dimensions allow for three pallets per level, the palletto-pallet gap may be adjusted to 80 mm. 

Number of Levels Possible Height Wise Table
Frame Height 2 Levels 3 Levels 4 Levels 5 Levels
3,000mm Yes Yes
3,500mm Yes Yes Yes
4,000mm Yes Yes Yes
4,500mm Yes Yes
5,000mm Yes Yes Yes
5,500mm Yes Yes Yes
6,000mm Yes Yes Yes

Frequently Asked Questions

What Can be Stored?

Palletised materials are stored horizontally across multiple levels, with compatible material handling equipments: Forklifts, Reach Trucks, Stackers, Stacker Cranes, etc. which are used to load and unload pallets onto the racks. Perfect for products/ inventory with multiple SKU’s, inventory/ goods with FIFO (First-In, First-Out) movement, medium-heavy weighted goods/ inventory. It gives direct access to each pallet without disturbing/ having to move others.

Your order will take at least 6 days to process plus the additional time taken for delivery shown at your checkout when it is finalised. In many cases, the processing time can
change too.

For Heights upto 3,500mm you will need a team of 4-7 people, for heights upto 6,000mm you will need a team of 7-9 people. 1 Main Bay usually takes 1hour depending on the skillset and tools used.
Because main bays or starters are the only units that can stand alone, you will need one for every run and one for every standalone unit in your warehouse layout. This makes calculating the number of starters you need simple. Determine how many runs and standalone units you need — that’s the number of starters you should purchase.

Add-ons are for continuous runs, and these calculations require more thought. Consult your layout to determine how many continuous runs you need to outfit. Then, record the number of bays each run will have. If your warehouse has 10 runs with 14 bays per run, you’ll need 13 add-ons for each run. Multiplying 13 add-on bays for each run by 10 runs is a total of 130 add-on bays.

While ordering a basic Main Bay, you will get all the required main components in your order — 4 uprights, its necessary quantity of horizontal and diagonal bracings, 4 upright legs, 4 levelling shims, 2 load beams for each level, & 4 lock pins for each level. All the necessary hardwares and fasteners are also provided in the required quantities to anchor and secure the mentioned components.

While ordering a basic Add-on Bay, you will receive — 2 uprights, its necessary quantities of horizontal and diagonal bracings, 2 upright legs, 2 levelling shims, 2 load beams for each level, & 4 lock pins for each level. All the necessary hardwares and fasteners are also provided in the required quantities to anchor and secure the mentioned components.

Along with these main components, any other accessory or extra component added in your order will also be sent with its required fasteners.

No tools will be provided and we may provide extra fasteners in our kits.

Of course, all the assembly instructions and user manuals are also provided. A digital
copy of the same will be available for you in your account as a backup too.

Absolutely. We know that choosing the right rack system can feel overwhelming. You can explore our support and design services here to get step-by-step assistance.

Our support team is available Monday to Friday, 9:00 AM to 5:00 PM (IST). You can reach us at [email], and we’ll get back to you promptly.

Once a product has been shipped, cancellations and returns are not accepted. For full details, please review our policies here.

Our Promise

At Storix, we prioritise earning our customers’ trust through superior design, quality, and safety in every aspect of our PMR systems. Our solutions incorporate carefully designed components, that ensure efficient storage and ease of use. We follow the highest design standards to maximise space utilisation while prioritising operator safety, creating systems that are both reliable & user-friendly, and also safe for the environment.

Installation is seamless and hassle-free, allowing customers to experience immediate benefits without unnecessary delays. Our premium quality lead-free powder coating enhances durability, ensuring a longer product life while maintaining exceptional performance under rigorous conditions. With Storix, customers can trust in a system that delivers unmatched reliability, safety, and convenience.

More About Pallet Racking

Consider Storix PalletMax Rack for its most superior and conventional design offering seamless accessibility, robust durability, and efficient storage for diverse inventory needs.

  1. Adaptability: easily adapts to different product sizes, weights, and specifications, making it suitable for a wide range of industries. Organise and retrieve goods quickly, boosting productivity across your warehouse.
  2. Accessibility: Every pallet is easily and directly accessible without the need to move others, ensuring precise stock control and seamless inventory management.
  3. Optimal Stock Flow: Simplifies tracking, retrieval, and management of stored goods.
  4. Easily Modifiable: Its modular design allows for quick installation, expansion, or part replacement without disruptions. You can easily scale your storage effortlessly as your business grows or inventory changes.
  5. Versatility: Perfect for businesses requiring FIFO (First-In, First-Out) inventory management, ensuring goods move efficiently.
  6. Excellant ROI.


If Your Products…

  1. Require frequent or continuous loading and unloading. For example: clothing, electronics, toys, spare parts, groceries, etc.
  2. Need individual pallet accessibility with a variety of SKU’s. For example: medicines & drug variants, packaged items like food or beverages, etc.
  3. Have a high turnover and require FIFO (First In-First Out) management. For example: expiry sensitive items like food or medicines, seasonal cosmetics or clothes, fresh produces, etc.
  4. Demand flexible storage for varying product sizes and quick retrieval for fast order fulfilment. For example: a range of small to large electronic appliances, building materials like cement bags or tools of various sizes, car parts, small automotive accessories to large engine components, etc.
  5. Are heavy or bulky, requiring optimal use of vertical space with easy access for picking and organised stocking. For example: tires, car batteries, medium weight tools, etc.
  6. Are sensitive or time bound, requiring efficient stock control. For example: vaccines, perishable items, high demand products, etc.
  7. Are fragile yet medium to heavy in weight. For example: glass bottles, fragile containers, delicate items, medium weighted furniture, etc.
  8. Require a durable and versatile storage solution. For example: medium weighted machine parts, bricks, tiles, etc.

Different Methods of Storage & Retrieval on Pallet Racks:

  • FIFO — First In, First Out
    • Meaning: The first pallet stored is the first one retrieved.
    • Where is it Used: Essential for perishable goods, pharmaceuticals, food and beverages, or anything with an expiry date.
    • Types of Racking Systems: Drive-through racks, pallet flow racks (gravity flow), pushback (when designed accordingly).
    • Benefits: Ensures older stock is cleared first, minimising obsolescence or spoilage.
  • LIFO — Last In, First Out
    • Meaning: The most recently stored pallet is the first one retrieved.
    • Where is it Used: Common in non-perishable goods, bulk storage, and when space utilisation is more important than rotation.
    • Racking Systems: Drive-in racks, push-back racks.
    • Benefit: Maximises density in limited warehouse space.
  • Random Access — Selective Storage
    • Meaning: Any pallet can be accessed at any time, regardless of when it was stored.
    • Where is it Used: General warehouses, distribution centers, e-commerce, mixed SKU
      storage.
    • Racking Systems: Selective pallet racking (the most common type).
    • Benefit: High accessibility, simple operation, flexibility for varied products.
  • Batch Storage — Block or Bulk Storage
    • Meaning: Pallets of the same SKU are grouped together in blocks, often stacked or
      stored in deep-lane systems.
    • Where is it Used: Warehouses handling fewer SKUs but in larger volumes.
    • Racking Systems: Drive-in racks, double-deep racks.
    • Benefit: Efficient for bulk handling and maximising storage density.
  • Dynamic/ Flow Storage
    • Meaning: Uses gravity rollers or conveyors so pallets automatically flow from loading
      side to picking side. Usually FIFO.
    • Where is it Used: High-volume distribution centers, cold storage, high-velocity SKUs.
    • Racking Systems: Pallet flow racks, carton flow racks.
    • Benefit: Automatic stock rotation, reduced handling, faster picking.
  • Sequential — Zone or Wave Picking
    • Meaning: Goods are stored and retrieved in a planned sequence, sometimes combining FIFO/LIFO with order-picking logic.
    • Where is it Used: Automated warehouses, AS/RS systems.
    • Racking Systems: Mobile racking, shuttle systems, ASRS (Automated Storage and Retrieval Systems).
    • Benefit: High efficiency in order fulfilment, integrates with WMS (Warehouse Management Systems).

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