A 1,000 x 1,200 mm pallet does not by itself determine the rack dimensions. Its orientation, the size of the loaded goods and the clearances around each position also matter. Use the Pallet & Rack Size Planner to prepare preliminary dimensions for a review.
1. Define the orientation and loaded envelope
In this illustrative example, the pallet is 1,000 mm wide along the beam and 1,200 mm deep from front to back. Two pallets sit side by side, each with a gross weight of 1,000 kg including pallet, goods and packaging. This is a planning example, not a delivered customer project or an approved rack design.
Measure the load as well as the pallet. If cartons, wrapping or goods extend beyond its edge, use the larger occupied width when calculating the opening. The loaded depth is recorded separately from pallet support depth.
2. Calculate the clear bay width
Clear bay width = number of pallets × occupied width + 2 × upright clearance + (number of pallets − 1) × clearance between pallets.
With example clearances of 75 mm at each upright and 75 mm between the pallets: 2 × 1,000 + 2 × 75 + 1 × 75 = 2,225 mm. If each loaded pallet occupies 1,100 mm in width, the same calculation gives 2,425 mm.
The 75 mm allowance is editable example data, not a universal minimum or safety standard. Required clearances depend on handling equipment, storage height and the project. The result is a preliminary clear opening, not overall rack width or a confirmed catalogue beam length.
3. Review depth and pallet support separately
If a pallet supplier has confirmed that this pallet can be supported on beams in the selected orientation, example front and rear overhangs of 50 mm would give a reference frame depth of 1,200 − 50 − 50 = 1,100 mm. These overhangs are also editable examples, not approved limits.
Without confirmation of pallet suitability and support orientation, the tool withholds the reference depth. Pallet runners, beam bearing surfaces, support spacing and actual overhang must be reviewed. Additional decking or supports may be needed; floor-stacking suitability alone does not confirm beam-supported suitability.
4. Do not confuse required weight with rack capacity
Two gross loads of 1,000 kg create a requirement of 2,000 kg per level. That arithmetic is not a rated capacity. Pallet contact loads may differ from uniformly distributed loading. The existing Q235 beam table contains theoretical per-level values under uniformly distributed loading and does not approve this pallet arrangement or the complete rack.
5. Send a complete sizing brief
- Pallet width, depth, orientation and supplier support information.
- Loaded dimensions, gross weight per pallet and positions per level.
- Proposed clearances and front/rear overhang.
- Forklift model, lifting height, warehouse plan and project location.
- Required rack levels, quantities and any decking or accessories.
Calculate your preliminary dimensions, then use the tool’s sizing-review link to carry the inputs and result into the inquiry form. Review warehouse racking options or contact Steely Metal before confirming specifications.