How to Measure for Pallet Racking: A Practical Guide (AS 4084-2023 Compliant)

Getting your measurements right is the first step toward a safe and efficient pallet racking setup. If you're fitting out a new warehouse or modifying an existing layout, accurate measurements save time, cost, and operational risk.

At ReadyRack, we know it’s not just about fitting racking into a space, it’s about ensuring your storage works with your operations and complies with safety standards. This guide reflects the requirements and best practices outlined in AS 4084.1:2023 and AS 4084.2:2023.

Step 1: Know Your Pallet Size

Your pallet dimensions and load characteristics determine your racking layout and clearances.

Standard Pallet Dimensions in Australia:

Australian Standard Pallet: 1165 mm × 1165 mm
Euro Pallet: 1200 mm × 800 mm

Measure:

Length, width, and full loaded height
Any overhang from the load (front/back and sides)

Clearance Requirements:

Vertical clearance between top of load and bottom of next beam: minimum 100 mm, but may vary depending on handling method and racking type.

Step 2: Measure Your Warehouse Space

Consider your available volume, not just floor space.

Key Dimensions:

Clear Height: From floor to the lowest overhead obstruction (sprinklers, lights, etc.)
Usable Floor Area: Deduct space for:
- Aisles (see below)
- Doors and access points
- Fire exits and egress routes
- Structural obstructions (e.g., columns)

Aisle Widths:

According to AS 4084.1:2023, minimum aisle width depends on forklift type and turning radius.
- Counterbalance forklift: typically 3500–4000 mm
- Reach truck: may be reduced to 2500–3000 mm
Maintain minimum clearances specified by AS 4084.1:2023 and manufacturer specifications.

Step 3: Choose the Right Frame Height and Depth

Frame Height

To calculate:

Number of storage levels (including floor level if applicable)
Pallet load height
Vertical clearance between each level (≥100 mm)
Safety gap (≈150 mm) above top beam

Example:

3 pallet levels (each 1200 mm load height)
2 × 100 mm clearance between levels
150 mm safety gap
2 x beam profile (usually 100mm)

= 3 × 1200 + 2 × 100 + 2 x 100 + 150 = 4150 mm → Select next higher standard frame (e.g., 4877 mm)

Frame Depth

For Australian standard pallets (1165 mm):
- Recommended depth = 840 mm, allowing ~162 mm overhang front and back.
For other pallet sizes consider 1219mm deep frames with mesh decks.

Step 4: Select Beam Length

Determine how many pallets per beam level.

Calculation:

Pallet width (e.g., 1165 mm)
Clearance between pallets: ≥75 mm
Clearance to uprights: ≥75 mm each side

Example (2 pallets):

75 + 1165 + 75 + 1165 + 75 = 2555 mm

Select nearest standard beam:

2591 mm = 2 standard pallets
2743 mm = 2 CHEP pallets with tighter clearance
3050 mm = 3 Euro or narrower pallets

Check that beam deflection does not exceed L/200 and is within serviceability limits.

Step 5: Consider Weight and Load Requirements

AS 4084.1:2023 requires racking to be designed for:

UDL (Uniformly Distributed Load) across each beam
Point loads from pallets, concentrated at bearer locations
Load combinations, earthquake conditions (if applicable), and deflection limits

What to Know:

Maximum pallet weight
Total UDL per level
Load rating signs must be affixed per AS 4084.2:2023, showing beam and bay capacity.

Step 6: Consider Accessories and Add-ons

To meet compliance and operational needs, consider:

Mesh Decks: For non-palletised loads or fire sprinkler access
Pallet Support Bars: For undersized pallets
Back Stops: To prevent pallet push-through
Rack End Guards / Frame Protectors: Required at aisle ends to prevent forklift impact

Per AS 4084.2:2023, damage prevention and routine inspection of components like these is part of ongoing compliance.

Quick Checklist

Before placing your order, confirm:

✅ Pallet dimensions (L × W × H)
✅ Loaded pallet weight
✅ Vertical clearance per level
✅ Frame height (based on pallet stack + safety gaps)
✅ Frame depth (based on pallet type)
✅ Beam length and number of pallet positions per level
✅ Available floor and clear vertical height
✅ Aisle width (based on forklift type)
✅ Accessories required for safety and compliance
✅ Load signage to be provided onsite

Need Help? We’re Here for You

Our experts can walk you through load calculations, layout optimisation, and compliance with AS 4084:2023 standards. Whether you’re installing new racking or upgrading your existing setup, we’ll make sure it’s fit for purpose and fit for audit.