Drive in Racking

Drive-in pallet racking is a high-density storage solution in which the forklift truck enters the racking structure itself to place pallets on support rails. It is the right choice when the priority is to maximise storage capacity and the operation involves large volumes of the same SKU, where compaction is more important than direct access to every individual pallet. It is a cost-competitive solution, though it requires well-planned operating procedures and experienced forklift truck operators, as cycle times can be slower than in other systems.

The key difference lies in the direction of material flow. In drive-in pallet racking, loading and unloading take place from a single face, which means the system operates on a LIFO (Last In, First Out) basis — the last pallet placed in a lane is the first to be retrieved. In drive-through racking, access is available from both ends of the structure, which allows loading and unloading to be separated and supports a more orderly FIFO flow. However, this requires additional aisles and reduces overall storage density. Where FIFO rotation or tight stock traceability are critical, solutions such as pallet shuttle or FIFO live racking may be more appropriate.

Drive-in racking can be a strong option for cold stores because of its high compaction, which reduces the refrigerated volume of air and lowers energy costs. Where stock is held in large quantities of the same product — as is common in food production or cold chain logistics — the system makes efficient use of the available space.

However, the LIFO operating logic should be considered carefully in cold store applications where perishable goods require strict rotation. If FIFO management is essential, FIFO live racking or pallet shuttle with FIFO capability should be considered instead.

There is no single structural limit that applies to all projects. Height and depth are defined by the characteristics of the building, the handling equipment, the load specifications, and the specific operational requirements of the installation.

AR Racking designs every project individually in accordance with EN 15512. Heights are determined by the forklift truck capability and the available clear height of the building.

Safety is addressed from the design stage by defining correct clearances, lane geometry, and approach dimensions for the handling equipment in use. AR Racking designs its drive-in structures to withstand the horizontal impact forces specified in EN 15512, and can include additional protective elements such as column guards at lane entries, base plates, and end-of-aisle barriers.

Operational discipline is equally important: operators must be well trained and follow defined procedures, as the forklift truck enters the structure and the risk of accidental contact is inherently higher than in conventional racking.

The system can be used with various types of handling equipment, provided that the truck dimensions are compatible with the lane clearances. Counterbalance forklift trucks and reach trucks are the most common choices, though the specific model and mast configuration must be assessed to confirm that adequate clearances can be maintained within the lane.

AR Racking calculates lane widths, clearances, and structural parameters in relation to the equipment specified for each project.

Yes. Drive-in racking can be combined with other storage systems within the same warehouse by allocating separate zones for each solution. For example, drive-in lanes can be used for high-volume, low-SKU products, while adjacent selective racking or medium-duty shelving handles references that require direct access or individual picking.

A combined layout allows the warehouse to benefit from the density of drive-in storage where it is appropriate, without sacrificing accessibility for the remainder of the stock.

For drive-in racking to function correctly, it is strongly recommended that each lane is dedicated to a single SKU or batch. In this way, the LIFO constraint does not create traceability issues, as all pallets in the lane belong to the same product and lot.

Where strict FIFO rotation is required — for example, with products carrying a use-by date or batch release requirement — drive-in racking is not the most appropriate solution. In these situations, FIFO live racking or pallet shuttle with FIFO capability should be considered.

AR Racking’s drive-in racking systems are designed and calculated in accordance with EN 15512 and the relevant technical recommendations applicable to steel storage systems. The structures are manufactured in AR Racking’s own facilities under ISO 9001 quality management and ISO 14001 environmental management certification.

Components are marked and traceable through the Traceability 4.0 system, and all installations are supplied with the mandatory load notice and technical documentation.

A drive-in installation requires the same maintenance approach as other industrial racking systems, following the guidelines set out in EN 15635. This includes periodic visual inspections by a trained Racking Safety Inspector (RSI), assessment of any damaged components, and prompt replacement of any elements that have been deformed or struck by handling equipment.

Given the nature of drive-in operations — where the forklift truck enters the structure — the risk of minor impacts is higher than in conventional racking, and inspection frequency should reflect this.

SEMA (Storage Equipment Manufacturers’ Association) publishes specific guidance for drive-in pallet racking, including requirements for upright protectors, bay depth limits, and load notices. Drive-in racking systems require operators to manoeuvre forklift trucks inside the structure, which increases the risk of impact damage compared to selective racking. SEMA guidance recommends fitting column guards at vulnerable positions and conducting more frequent visual inspections in high-traffic operations. AR Racking designs its drive-in pallet racking systems with these operational realities in mind, and can advise on appropriate safety accessories — including upright protectors and end-of-aisle barriers — as part of the project specification.