How to calculate racking load capacity: the complete guide

Racking systems are essential elements for organizing and managing space in many work environments, such as warehouses, factories, and retail stores. When properly designed, these support structures contribute to space optimization and operational safety.

Moreover, correctly calculating the load capacity of racking systems is essential to prevent accidents and ensure a smooth workflow. In this article, we will understand how to calculate racking load capacity by following current regulations and industry best practices. Let’s get started!

1. Understanding racking specification

Every racking system is designed with specific technical characteristics, including maximum load capacity, which indicates the maximum weight that each level can support without compromising the structure. It is important to comply with these specifications not only through proper staff training, but also through careful installation and ongoing maintenance, ensuring that the racking operates within the prescribed safety limits.

2. Reading the load rating plate

Professional racking systems must be equipped with a clearly visible load rating plate that provides essential information, such as:

• Series and model
• Upright and level load capacity (uniformly distribuited)
• Year of manufacture
• Load unit (dimensions and weight)
• Height of the first level
• Total number of levels

This data is essential for calculating load capacity and ensuring that the racking is not overloaded.

3. Calculating the maximum load capacity of each level

To determine the maximum load capacity of each level, it is necessary to divide the total load capacity of the racking system by the number of levels. This operation helps to understand how much weight can be evenly distributed on each level.

Calculation example:

If a racking system has a total load capacity of 10,000 kg and consists of 5 levels, the maximum load capacity of each level will be:

Load per level = 10,000 kg / 5 levels = 2,000 kg

It is also important to verify that the load capacity per level is compatible with the load capacity of the beams.

4. Load distribution

To maintain maximum load capacity, it is essential to distribute loads evenly across the shelves. In fact, improper distribution—such as placing heavy loads on one side of a shelf—can compromise the stability of the racking and reduce its actual load capacity.

5. Considering the distances between levels

The distances between levels affect the load capacity of the racking system. The greater the distance between levels, the lower the load capacity of the upright. Racking systems are designed with specific maximum distances between levels: exceeding these limits can compromise safety and stability.

6. Load placement

A good approach is to place heavier loads on the lower levels and/or in contact with the ground, where possible. This improves the overall stability of the racking system.

7. Maintenance and safety

The maintenance of racking systems is essential to ensure their safety and efficiency over time. It is mandatory to carry out periodic inspections in accordance with the UNI EN 15635 standard. These inspections must be performed by qualified technicians at least once a year and must include a detailed report on the condition of the racking and any required interventions.

Company responsabilities:

• Appointment of a PRSES (Person Responsible for the Safety of Storage Equipment): this role is responsible for carrying out regular visual inspections and in-depth checks.
• Record keeping: inspection documentation must be stored and made available in the event of inspections by competent authorities.

Armes racking systems

Armes designs each racking system according to strict technical standards, including structural checks that determine the maximum load a racking system can support. Another key factor is load distribution, which must be uniform to avoid overloading specific sections of the structure.

These criteria are based on national and European standards—such as UNI EN 15629 and UNI EN 15512—which regulate the design and installation of racking systems and ensure structures optimized for maximum safety and functionality.

To meet different storage needs, it is essential to adapt the system to the warehouse layout. For this purpose, Armes offers solutions that can be customized according to customer requirements, including:

• Automated storage systems: these enable efficient and technologically advanced warehouse management, making intensive use of available space to optimize the entire storage area.
• Pallet racking: consisting of uprights connected by horizontal beams, designed to facilitate the storage of palletized goods, simplifying access and load handling.
• Cantilever: dotate di un sistema a mensola, ideale per immagazzinare materiali lunghi o voluminosi come tubi, profilati e pannelli, ottimizzando lo spazio disponibile.
• Gravity racking: solutions available in both light and heavy versions, ideal for high-density storage of homogeneous products. The light system is suitable for lower-weight goods, while the heavy system is designed for pallets. Both are equipped with roller systems that enable movement by gravity.

Each system is designed to withstand the intended loads without compromising operational safety, while ensuring optimization of space and logistics processes.

Certifications and regulations for racking systems

In addition to Legislative Decree 81/2008, which protects health and safety in the workplace, Armes is committed to strictly complying with all relevant technical industry regulations. Among these, UNI EN 15635 is fundamental for the safe management of racking systems, establishing rules for maintenance and regular inspections in order to prevent overloads or structural damage.

Furthermore, the company follows UNI EN 11636, which governs procedures for the inspection and periodic verification of racking systems, ensuring durability and ongoing compliance over time.

Conclusion

Calculating racking load capacity and ensuring regular maintenance are essential aspects for the safety and efficiency of storage spaces. Relying on experienced partners such as Armes allows you to implement tailored solutions that comply with regulations and are designed to last over time.

If you are planning a storage system and/or need to ensure compliance with current regulations, do not hesitate to contact us.