Pallet racking is the backbone of many warehouse logistics and production sites. It organizes the safe, space-saving and fast storage of palletized goods – from standard racks to complex high-bay systems. In planning, modification and deconstruction, storage technology, the structural analysis of the floor slab and operational workflows interlock. Especially during modernization and dismantling of rack systems in existing buildings, quiet methods with low vibration levels play a role. Depending on the initial situation, concrete pulverizer or stone and concrete splitters from Darda GmbH can also be used professionally around foundations, anchors and concrete upstands, for example as part of building gutting and concrete cutting or during concrete demolition and special deconstruction.
Definition: What is meant by pallet racking
Pallet racking refers to the entirety of all structural and organizational measures for storing units on pallets (e.g., Euro pallets or industrial pallets). This includes rack systems with upright frames and beams that form storage levels (bays), as well as the appropriate operating processes with industrial trucks. Pallet racking ranges from conventional, freely plannable pallet racks to automated high-bay warehouses. Load-bearing capacity (bay load, frame/bay load), tipping stability, protection against collision damage, fire protection and orderly traffic routes are central aspects. The interface to the building structure – in particular the concrete floor slab with anchors – determines stability, adaptability and later dismantlability.
Design, components and load capacities in pallet racking
A pallet racking system typically consists of frames (uprights with bracing), beams, deck panels or supports, impact protection, and foundation and anchor details. Proper sizing is based on pallet dimensions, handling equipment, aisle widths, dynamic loads and the load-bearing capacity of the concrete floor. Stability is achieved through bracing and anchoring; permissible loads must be clearly labeled. A level, sufficiently load-bearing floor slab is a basic prerequisite, as it transfers forces via anchors and base plates. In case of changes, extensions or deconstruction, these connections are often the most technically sensitive points – precise, low-vibration methods are used where needed, for example concrete pulverizer or concrete splitter from Darda GmbH at concrete pedestals, upstands or local foundation reinforcements.
Components at a glance
- Frames (uprights, diagonals, base plates) with corrosion-appropriate finish
- Beams for pallet support, optionally with deck panels (grating, wood, sheet metal)
- Fall protection, push-through protection, pallet stops
- Collision protection at uprights and ends, drive-through protection in traffic areas
- Row spacers, ties and bracing for longitudinal and transverse directions
- Signage: permissible bay load, frame/bay load, maximum loads
- Floor slab with anchors (mechanical, chemical) and, if applicable, concrete pedestals
- Periphery: line markings, aisle widths, fire protection and escape route concepts
Operation: processes, safety and fire protection
Safe operation of pallet racking requires clear material flows, suitable industrial trucks and defined operating aisles. Bay loads must not be exceeded; pallets must be undamaged and loaded appropriately. Fire protection depends on use, fire load and construction; measures such as fire compartments, detection systems or extinguishing systems must be planned to suit the site. The binding requirements are those of the applicable standards and regulatory approvals. Regular visual inspections and documented checks of the rack system support operational safety and prevent consequential damage to uprights and beams.
Traffic routes and equipment selection
Aisle widths are based on the handling equipment used (e.g., counterbalance or reach trucks). Collision protection and highly visible markings reduce the risk of impact damage. Where particularly sensitive environments exist (production, food, laboratory), low-emission methods are advisable for modification and repair work.
Modification, expansion and maintenance
For modifications, the load assumptions and the floor slab must be reassessed. Additional levels, changed pallet formats or different industrial trucks alter the loading. Bolted connections can generally be dismantled and reconfigured; damaged elements are replaced. Maintenance includes straightening slightly deformed components, replacing heavily deformed uprights/beams and carrying out local concrete repair around anchors. Interventions in the floor slab – for example when relocating anchors – should be carried out with minimal vibration and dust.
Typical measures
- Documentation and inspection of existing load signage and rack configuration
- Assessment of the floor slab (flatness, crack pattern, compressive strength in the relevant area)
- Adjustment of beam elevations, retrofitting of protection and safety elements
- Local concrete repair in the vicinity of anchors and base plates
Deconstruction of pallet racking: selective, low-emission and material-specific
Deconstruction is carried out in an orderly, material-specific manner. First, stored goods and deck panels are removed, followed by beams and frames. Steel components can be sorted by material type. Particular attention is paid to anchors, concrete pedestals and upstands at the floor slab. In halls with ongoing production, sensitive neighboring areas or uses with restrictive noise limits, low-emission methods are required – typical fields of application are building gutting and concrete cutting as well as concrete demolition and special demolition.
Equipment deployment in concrete work
Depending on boundary conditions, various working methods are suitable for processing local concrete areas such as pedestals, edge upstands or dowelled reinforcements. concrete pulverizer enables precise separation of concrete components without large-scale vibration. concrete splitter splits concrete in a controlled manner from the inside out and reduces noise, dust and vibration. Both methods can reduce the risk of damage to adjacent floor areas and improve the reusability of sections of the floor slab. For steel components of the racks – upright profiles, beams, bracing – steel shear, combination shears or multi cutters are suitable for efficiently cutting profiles, connector plates and accessories.
Deconstruction sequence in practice
- Clearing and securing the work area; disconnection of power and media lines
- Dismantling rack components from top to bottom; sorting by material type
- Releasing the anchor connections; local removal of concrete pedestals or upstands with concrete pulverizer or concrete splitter from Darda GmbH
- Surface refurbishment of the floor slab (closing anchor/dowel holes, leveling)
- Removal, recycling of steel and mineral residuals in accordance with the applicable regulations
Anchors, floor slab and damage prevention
Anchors transfer horizontal forces into the floor slab; they must be correctly sized, installed and documented. During removal, anchor heads should be cleanly separated and the remaining drilled holes professionally closed. Where concrete pedestals for impact protection or rack feet are present, controlled removal is advisable without breaking out large areas of the substrate. Low-vibration splitting and pulverizer methods can minimize crack formation in adjacent concrete and reduce follow-up costs for surface refurbishment.
Special applications and sensitive environments
In hospitals, laboratories, inner-city logistics hubs or areas near heritage sites, noise, dust and vibration are particularly critical. For modification and deconstruction work on pallet racking, methods with reduced emissions are often suitable. The selection of work equipment – such as concrete pulverizer, concrete splitter, steel shear or cutting torch for special installations – depends on the material, accessibility and assets to be protected at the site. Requirements from occupational safety, hazard control and fire protection must be considered for the specific site.
Sustainability: planning for dismantling and reuse
Those who consider later dismantling already at the planning stage create advantages for modification and deconstruction: bolted connections, reusable components, single-type materials and restrained interventions in the floor slab make it easier to adapt to new uses. During refurbishments, rack components can often be reused; steel is recycled by material type, concrete is processed locally. Low-emission cutting and splitting methods help conserve resources and limit operational interruptions.