As your business grows, your warehouse needs to grow with it. Whether you’re storing more stock, scaling operations, or diversifying your inventory, there comes a point when your existing racking setup just isn’t cutting it anymore. But expanding your racking isn’t just a matter of buying more shelves and fitting them in. Without a plan, you could end up with a chaotic layout, safety hazards, and wasted space.
Here’s a clear, practical checklist to help you get it right the first time.
1. Assess Your Current Storage Situation
Before you make any changes, take a good look at your current setup:
- Are you using your vertical space effectively?
- Do you have aisles that are too wide or poorly placed?
- Is your current system meeting pick rates and operational flow?
- Are there areas of recurring congestion or safety incidents?
A thorough audit will uncover inefficiencies and show whether expansion is the best solution or if layout optimisation could deliver better results.
2. Forecast Your Future Needs
Expansion should solve tomorrow’s problems, not just today’s. Sit down with your operations team and consider:
- Expected growth in SKUs and pallet volume
- Seasonal peaks and trends
- Changes in order picking methods (e.g. batch vs. single)
- Introduction of automation or new equipment
Planning with a 3- to 5-year horizon can help prevent premature obsolescence and rework.
3. Measure Twice, Install Once
Accurate measurements are non-negotiable. Map out the exact dimensions of your warehouse, taking into account:
- Ceiling height and clearances
- Column placement and structural obstructions
- Fire exits and equipment pathways
- Lighting, sprinklers, and ventilation
This information is crucial when working with a racking supplier to ensure compliance and maximise capacity.
4. Review Compliance and Safety Requirements
All racking systems in Australia must comply with AS 4084-2023. When planning your expansion:
- Confirm your new layout meets load ratings and aisle width guidelines
- Plan for safe forklift turning circles and clear pedestrian paths
- Schedule post-installation inspections
Your racking supplier should assist with engineering certification and signage to meet legal requirements.
5. Choose the Right Racking System
Not all racking is created equal. Your choice depends on the nature of your stock and how frequently it moves:
- Selective Pallet Racking – versatile and accessible; great for varied inventory
- Drive-In Racking – maximises space for high-volume, low-SKU items
- Cantilever Racking – ideal for long, awkward items like timber or piping
- Long Span Shelving – better for smaller parts or cartons
Discuss your options with a professional to ensure you get the right fit. You can explore our pallet racking solutions for more detail.
6. Minimise Disruption to Operations
Adding racking while still running your warehouse can be tricky. A good supplier will help plan the project in stages to avoid major downtime. Strategies may include:
- Staggered installation over weekends or low-volume days
- Temporary storage areas
- Prioritising high traffic zones first
Communication between your operations team and installers is key to keeping things moving.
7. Factor in Equipment Compatibility
Make sure your forklifts, order pickers, and material handling equipment are compatible with your new layout. Consider:
- Aisle widths vs. turning radius
- Height reach of lifting equipment
- Floor load limits
If you’re upgrading to higher racking, you may need new machinery, or attachments that improve reach and stability.
8. Plan for Future Flexibility
Warehouses evolve. Your racking should, too. Build flexibility into your layout by:
- Choosing modular racking that can be adjusted
- Leaving space for future expansion zones
- Installing mezzanine flooring if you expect vertical growth
Check out our mezzanine flooring solutions if you’re looking to scale up without changing premises.
9. Work With a Professional Racking Partner
An experienced racking provider like Erect-A-Rack brings more than just products we bring planning, compliance, safety, and reliability. We take the time to understand your workflow and deliver tailored solutions that are built to last.
Whether you’re expanding a small warehouse or scaling up a major operation, we’ll help you do it right.
Ready to expand your warehouse the smart way? Contact us today to get started.
