American-Style Pallet Racking for US Client: 544 Pallet Positions in a 24,384 x 30,480 mm Warehouse

Project Overview

This American-style pallet racking project was delivered for a US-based distribution client who needed to convert a 24,384 x 30,480 mm warehouse into a dense, high-throughput storage facility. Starting from the client's own full-size racking drawings, pallet data and a single central door position, our engineering team produced the complete selective pallet racking layout, bill of materials and installation drawing set that fits the building envelope exactly, with no column conflicts, no wasted floor area and a clean forklift circulation path.

Project Data at a Glance

Layout Design: Two Wall Rows and Four Back-to-Back Rows

The 30,480 mm building length carves into a repeating 2,340 mm double-pallet bay module, which is what allows the client to store two 1,016 mm wide pallets per level. Total usable storage length is 68 bays, split into six independent runs:

• Wall-side rows: two single rows placed directly against the 30,480 mm walls, 12 bays each, giving the highest possible storage density along the building perimeter.
• Central block: four back-to-back rows of 11 bays each, configured as two pairs of back-to-back runs with a one-pallet-position gap left between the pairs so that forklifts can pass through the middle of the block.

The door sits at the midpoint of the 24,384 mm wall, so the main aisle axis runs straight from the door into the central passage. That single decision keeps travel distances short, keeps the two wall rows fully reachable from both ends, and avoids any dead-end aisle that would slow down picking.

Engineering Highlights

• Beam sizing: 2,340 mm beams were selected so each bay takes two 1,016 mm pallets with 308 mm of total operating clearance, which is comfortable for a 900 kg load handled by standard warehouse forklifts.
• Height structure: four beam levels per bay give 544 pallet positions inside a footprint that would only hold around 130 pallets if floor-stacked to the same load height.
• Forklift circulation: the central one-pallet-position passage lets trucks cross the block without backing out, cutting the most common cause of rack impact damage in US warehouses.
• Drawing package: the client's original general-arrangement drawing was rebuilt into a shop-ready set with upright positions, beam elevations, bay-by-bay pallet counts and anchor plans, so the installer could work straight from the sheets.

What the Client Received

• Complete American-style selective racking layout on the client's own warehouse drawing.
• Bill of materials covering uprights, 2,340 mm beams, four beam levels, cross bracing, footplates and anchors.
• Bay-by-bay pallet position schedule confirming 544 positions across 68 bays.
• Clearance and aisle plan aligned to the central door so that inbound and outbound flows never cross.

Project Outcome

The final layout turns a 24,384 x 30,480 mm shell into a 544-position selective racking warehouse built around 900 kg pallets, 2,340 mm beams and four storage levels. Because every bay, aisle and clearance was resolved on the drawing before production, the client could order once, install straight through, and start receiving stock with no rework and no lost floor space.