Warehouse safety and efficiency start with one crucial factor: load ratings. Whether you’re installing a pallet racking system or building a mezzanine floor, understanding the maximum load capacity of your storage setup is essential to protect your team, stock, and equipment.
In this guide, we break down everything you need to know about pallet racking load ratings, mezzanine floor weight capacity, and how to calculate rack load limits safely and in line with Australian Standards.
What Are Load Ratings in Racking?
A load rating refers to the maximum weight a storage system can safely support. This rating applies to:
- Pallet racking systems (e.g. selective, cantilever, or push-back racks)
- Mezzanine racking systems (elevated storage platforms built using racking)
All commercial racking in Australia must comply with AS 4084-2023 — the current Australian Standard for steel storage racking. This standard requires that racking systems be rated and signed accordingly to prevent overloading.
Pallet Racking Load Ratings
Pallet racking load ratings depend on a few key elements:
- Beam capacity – How much weight each horizontal beam can support
- Frame capacity – The vertical upright’s load-bearing strength
- Bay spacing – The distance between uprights
- Number of beam levels – More levels = more weight on the frame
For example, a typical selective racking bay with 2 beam levels might be rated to support 2,000–3,000 kg per level, depending on beam size and span.
Important: Load ratings are based on uniformly distributed loads (UDL), not point loads. An unevenly loaded pallet can exceed localised weight limits and cause rack failure.
Mezzanine Racking Load Ratings
Mezzanine floors constructed from pallet racking frames must also be rated based on:
- Live load – Dynamic weight from people, stock movement, trolleys, etc.
- Dead load – The structure’s own weight
- Point loads – Heavy machinery or pallet jacks on wheels
- Span of the flooring system – Wider spans require stronger support
In Australia, most mezzanine floors are engineered to support between 2.0–5.0 kPa, which equates to 200–500 kg per square metre — but this depends on usage and site conditions.
How Much Weight Can Racking Take?
There’s no universal answer — racking load capacity depends on:
- The type of racking (selective, cantilever, mezzanine, etc.)
- The quality and size of beams and uprights
- The configuration of bays and levels
- The type of flooring and slab thickness
- The condition and age of the racking
As a rough guide, most standard racking systems support 1,000 kg to 3,000 kg per level, but high-capacity systems can exceed 6,000 kg per bay when properly engineered.
What Is Racking Strength?
Racking strength refers to the structural capacity of the racking system to support vertical and horizontal forces. It’s affected by:
- Material thickness and steel grade
- Beam connector design and welds
- Upright bracing and anchoring
- Load distribution and rack height
A strong racking system resists collapse from overloading, forklift impact, and seismic activity (where applicable). Racking strength should be verified during inspections and confirmed by the manufacturer or a qualified racking engineer.
Understanding load ratings is more than a compliance issue — it’s a critical part of warehouse risk management. Whether you’re designing a new warehouse layout or upgrading your existing systems, confirming your pallet racking and mezzanine load capacities is essential for safety, efficiency, and compliance.
If you’re unsure about the current rating of your racking system or want to ensure you’re meeting AS 4084-2023 standards, contact TQA for a professional pallet racking audit. Our team can assess your setup, identify potential risks, and provide expert recommendations to keep your warehouse safe and fully compliant.