Racking systems
Racking systems – pallet racking, narrow-aisle, mobile and shelving racks – designed together with STILL trucks to make full use of your warehouse height and floor area.
Why racking and trucks must be planned together
Buying racking first and trucks later often leads to aisles too narrow for the truck, top beams above the lift height or bay loads that exceed the capacity at that height; aisles that are too wide cost pallet positions. Aisle width, beam levels and bay loads must match the trucks, so TCID plans racking and trucks together to avoid wasted space or the wrong truck.
Three parameters need to be fixed first:
- Working aisle width (Ast): decides between counterbalance trucks, reach trucks or very narrow aisle (VNA) trucks.
- Height of the top beam level: must be within the truck’s lift height, with a safety clearance above the pallet.
- Load per bay and per pallet: must suit the truck’s residual capacity at that exact height, not just the rated capacity. Reading the load chart is explained in how to choose forklift capacity.
Selective pallet racking for wide-aisle warehouses
Selective pallet racking is the standard solution for storing many different goods on pallets: direct access to every pallet, easy stock level monitoring, adaptability to the space and the goods, different load carriers in a single rack type, and order picking directly from the rack.
In wide-aisle warehouses the racks are usually served by counterbalance trucks, reach trucks or order pickers; the lower levels can be handled with hand pallet trucks or electric stackers. Where you need height but still want compact aisles, STILL reach trucks are a popular choice.
Shelf floors and rack protection
Beam levels take place-on or fit-in shelf floors: chipboard up to 38 mm thick or mesh grid depending on the load. Rack protection covers solutions inside the aisles and protection of end-face uprights, where trucks often strike when turning. Broader measures for people and trucks are covered on the warehouse safety page.
Narrow-aisle and VNA racking: higher storage density
Very narrow aisle (VNA) warehouses store large volumes on a small footprint, and modern VNA trucks are easy to automate. To get the full benefit, the warehouse must follow STILL’s VNA guidelines for the floor, rack layout and guidance.
Floor
The floor must be stable, oil-resistant, provide grip and be very level across the full aisle width; the higher the racking, the tighter the tolerances. Expansion joints should lie outside the wheel tracks. A non-compliant floor can be ground or milled across the full aisle width, with a transition ramp. Distributed load and wheel pressure are calculated for each truck type.
Rack installation and clearances
Racks are installed within EN 15620 tolerances. Double-row racks need at least 100 mm between load units, with space for sprinkler pipes; transfer points should have a centring aid.
Rail or wire guidance
VNA trucks are guided by steel rails on both sides of the aisle or by an inductive wire in the floor. With wire guidance, the transfer aisle is based on truck length including load plus a margin of around 1,700 mm; the wire must avoid steel plates, manhole covers and cable ducts. STILL recommends erecting the racking first, then cutting the wire groove.
Suitable trucks: STILL MX-X (man-up, lift heights up to 18 m) and STILL NXV (man-down, 1,500 kg capacity). A detailed comparison is in our article on very narrow aisle forklifts.
Mobile racking and shelving
Mobile racking
Mobile racking places rack rows on rail-guided bases and opens an aisle only where goods are needed; it suits slow movers, tight sites or cold stores. Access is slower than selective racking, and serving trucks are chosen by the opened aisle width.
Shelving for boxes and small items
STILL shelving racks for cartons and small items: simple, modular, easy to expand, many accessories; options include inclined and transparent shelves, tyre and rim racks and racks for hazardous liquids.
Racking and STILL truck selection table
| Rack type | Best when | Serving STILL trucks | Design notes |
|---|---|---|---|
| Selective pallet racking, wide aisle | Many SKUs, direct access to each pallet | Counterbalance trucks, reach trucks, order pickers; hand pallet trucks and stackers for low levels | Aisle sized to the truck; protect end-face uprights |
| Narrow-aisle / VNA racking | Limited footprint, high building, large volumes | STILL MX-X, STILL NXV | Very level floor; rail or wire guidance; tight installation tolerances |
| Mobile racking | Slow movers, cold stores, small area | Reach trucks, counterbalance trucks | Slower access than selective racking |
| Shelving | Cartons, small items, spare parts, manual picking | Order pickers, electric pallet trucks | Modular, many accessories; options for hazardous goods |
For high selective racking, the STILL FM-X reaches stacking heights of up to 14 m; its narrow-chassis versions support more compact aisles. How to translate each truck’s Ast into a layout drawing is covered in warehouse aisle design.
How TCID delivers a racking system
- Site survey: measure the floor plan, clear height, floor condition, pallet types, load weights and number of shifts (1–3 shifts).
- Rack–truck pairing: propose rack type, aisle width, number of levels and bay load matched to the right STILL truck.
- Floor and guidance check: for VNA warehouses, review floor requirements, expansion joints and rail or wire guidance against STILL guidelines.
- Installation coordination: work with the racking supplier and floor contractor from the start so tolerances are planned in.
- Handover: test runs, operator instruction and scheduled maintenance; then you can expand into warehouse automation.
Frequently asked questions
Should we choose racking or trucks first?
Decide both together. Aisle width, top beam height and bay load depend directly on the truck; choosing separately easily leads to wasted space or having to change trucks.
Can an existing warehouse be converted to VNA racking?
Yes, after a floor check; insufficient flatness can be fixed by grinding or milling the aisles.
Can shelving be combined with pallet racking?
Yes: pallet racking for full pallets, shelving for small items and spare parts.
Does TCID support projects in both the North and the South?
TCID has offices in Hanoi and Ho Chi Minh City and the Long Binh Service Centre in Bien Hoa, Dong Nai, to survey and support projects.
Send us your floor plan, building height and goods data and TCID will propose a matching racking and STILL truck configuration.