ADJUSTABLE PALLET RACKING (APR)

Sizing Frames, Beams and Beam Levels

Frame depth follows the pallet: 900 mm for a 1200 x 800 mm Euro pallet stored 800 mm deep, 1,100 mm for a 1200 x 1000 mm CHEP pallet stored 1,000 mm deep, leaving a nominal overhang front and rear so the pallet bears on the beams and not on the frame. Bay width follows the pallet count: a two-pallet bay for 1,000 mm deep pallets is typically 2,700 mm clear, giving 75–100 mm between pallets and 75 mm at each upright.

Beams are rated as a pair and typically run 1,500 kg to 4,000 kg UDL depending on section height and clear span. Longer beams do not just cost more — capacity drops with span, so a 3,600 mm three-pallet bay needs a deeper beam section than a 2,700 mm bay to carry the same weight per pallet. We size against your heaviest loaded pallet, then check deflection, which is limited to span/200 under load.

Beam pitch is set from your tallest loaded pallet plus 100–150 mm lift clearance, and we always plan the top level so the load top clears sprinkler deflectors by at least 500 mm. Because uprights are perforated at 50 mm or 75 mm, levels can be re-set later with a rubber mallet and two people — that adjustability is the whole point of the system and the reason APR outlives the stock it was designed for.

• Frame heights from 2,000 mm to 12,000 mm
• Frame depths of 900 mm and 1,100 mm as standard
• Beam levels adjustable on 50 mm or 75 mm pitch
• Beam pairs rated 1,500–4,000 kg UDL
• Timber, chipboard or wire mesh decking for non-standard loads
• Column guards, end barriers and run-spacers fitted as standard

New Versus Used APR

APR has the deepest second-hand market of any racking type in Britain, which is exactly why buying used works so well here. Dexion Speedlock, Link 51 XL, Redirack, Apex, Stow, Mecalux and PSS all circulate in volume, so matching components are available years after a system was installed. Expect used to save a substantial share of new cost, with lead times often measured in days rather than weeks.

The rule that never bends: never mix beams and frames from different manufacturers. Connector lug profiles differ between brands, and a beam that looks seated may be engaging on a fraction of its intended bearing. We grade, sort and stock by brand so every order ships as a matched system, and we reject beams with cracked connector welds or twist, and uprights with dents beyond SEMA damage limits.

Protection, Load Notices and Inspection

Most APR damage happens in the bottom metre, from truck impact at the aisle end and at the pick face. Bolt-down column guards on aisle-end uprights and end-of-run barriers pay for themselves the first time a driver misjudges a turn. We specify heavier protection at goods-in and despatch where traffic density is highest.

Every run must carry a legible load notice showing bay load, beam-level load and configuration. HSE guidance HSG76 expects a nominated Person Responsible for Racking Safety, weekly recorded visual checks, and an annual inspection by a SEMA-approved inspector grading damage green, amber or red. Red must be offloaded immediately and the run isolated until repaired. Repairs use manufacturer-matched or SEMA-compliant repair components — never welded plates or straightened uprights, both of which invalidate the design.