25th May 2026
After more than 30 years installing and maintaining pallet racking in UK warehouses, the AHS team has seen what works, what fails, and what businesses tend to overlook. From initial design through to ongoing use, the same themes come up time and again: safety, planning, and making sure systems remain fit for purpose.
We asked members of the team to share their experience on the questions we hear most often. The answers below cover everything from when to review your warehouse racking to how to spot the warning signs that a system needs attention.
Rob:
“Well, before it becomes a safety or compliance issue.In most cases, the trigger isn’t the racking itself, it’s a change in operation. That could be different pallet sizes, increased weights, or higher stock volumes. A common example is when an FLT driver questions whether the racking can safely handle a new load.
If that question is being asked on the warehouse floor, the review should already be happening. Early assessment avoids risk and gives you more options.”
Ebony:
“Future growth should always be part of the conversation. Changes in layout, increases in stock volume, or a move into e-commerce can all affect how your pallet racking needs to perform. For example, you may need additional picking levels or different access requirements for faster order fulfilment.
If you only design for today, you often end up reworking the system sooner than expected. Planning ahead helps avoid unnecessary cost and disruption later.”
Fletch:
“Load signage provides clear, essential information to the people using the system every day.
Load notices for racking tell operators the safe working load for each beam level and the total load per bay. Without that visibility, you’re relying on guesswork, which increases the risk of overloading.
It’s a simple but critical part of maintaining a safe working environment, and one of the easiest details to keep up to date.”
Daisy:
“They are essential to keeping the system safe and compliant over time. Regular inspections help identify damage or wear early, before it becomes a larger issue.
Maintenance ensures the racking remains structurally sound and continues to meet required safety standards.
It is not just about compliance, it is about preventing avoidable risks and keeping operations running smoothly.”
Cat:
“Planning and communication are key. Where a warehouse needs to stay operational, a phased installation is often the best approach. This allows work to be completed in sections, so parts of the warehouse remain functional throughout.
Preparation also makes a significant difference. Clear working areas, good access, and the right equipment all help keep the project moving efficiently.
In some cases, working outside of peak hours, such as evenings or weekends, can further reduce disruption.”
Jack:
“There are some clear physical indicators:
These are all signs the system needs attention. Left unaddressed, they can affect the integrity of the racking. Damaged components such as racking clips should always be replaced before the affected bay is reloaded.”
Col:
“Some of the most widely used systems include Link 51, Dexion, Apex, and Stow pallet racking.
Each has its place, but the key consideration is compatibility, condition, and suitability for the specific operation. This is particularly important when working with existing installations or second hand pallet racking, where mixing incompatible components can compromise safety.
A reputable used racking company will be able to confirm exactly which system second-hand stock comes from, along with the original load ratings and safe working loads.”
Caron:
“Pallet racking should be treated as a long-term operational asset, not just a one-off purchase.
It has a direct impact on safety, efficiency, and how a warehouse can scale over time. When it is specified and maintained properly, it supports operations for many years and delivers far better long-term value.
Taking a more strategic view helps businesses get the most out of their investment, whether they’re working with new systems or used pallet racking.”
The AHS team works with businesses across the UK to specify, install, and maintain pallet racking systems for a wide range of industries. If you’d like to talk through a project, a system review, or an upgrade, get in touch and one of the team will be happy to help.
