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Help CenterCustom Size Steel Pallet Racking 1000kg to 4000kg Multi Level Beam Rack — Tailored to Your Warehouse Not the Catalog
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Why "Standard Size" Racking Never Fits Your Warehouse
Here's a story I hear every other week.
A machinery plant in Jeddah bought a "standard size" pallet racking online. When it arrived:
Beam spacing was 1.5m — their pallets were 1.8m high. Pallets wouldn't fit.
Rack width was 2.7m — their warehouse aisle was 2.5m. The rack wouldn't go in.
The supplier said "standard size can't be modified." They lost $2,800 in return shipping and delayed production by 3 months.
This is not a rare case. It happens because "standard size" means whatever the factory decided to mass-produce. It's convenient for them, not for you.
Our approach is the opposite: You tell us your dimensions, we build the racking. No catalog, no "pick from these 3 sizes." Just your warehouse measurements, your pallet sizes, your load requirements.
What Can Be Customized? (Real Examples)
Case 1: Pallet Too Tall or Too Short — Adjust Beam Spacing
This is the most common issue. Standard racking has fixed beam spacing (usually 300mm increments). But your pallets might be 1.2m (Euro standard) or 1.8m (common in Middle East).
How we handle it:
You give us your pallet height
We set beam spacing to exactly your pallet height + 50mm clearance
No wasted vertical space, no "too tight" fit
A Dubai plastic pallet manufacturer had standard racks where each level wasted 40% height. After custom spacing, they fit 2 pallets per level instead of 1. Storage density doubled. The racking cost only 5% more (custom hole punching), but they eliminated 2 entire rack rows — saving $8,500.
Case 2: Warehouse Has Columns or Corners — We Work Around Them
Warehouses are rarely perfect rectangles. There are columns, fire pipes, AC units protruding from walls, doors blocking sections.
A textile mill in India had this problem:
Factory measured 32m long, but 3 columns at uneven intervals
Standard racking plan: split into 4 sections of 8m each → wasted 6 pallet positions at column locations
Our solution: Designed around each column, creating "U-shape" structures where columns sat
Result: Warehouse utilization went from 70% to 88%, saving 600,000 INR ($6,800) per year in rent
What we need from you: A hand-drawn sketch (photo is fine) with column positions, door locations, and any wall obstructions. That's enough for us to draft a CAD layout.
What Customization Actually Costs (vs What You Think)
Most people hear "custom" and assume "expensive." Not necessarily.
Here's our pricing logic for custom racking:
| Customization | Cost Increase | Note |
|---|---|---|
| Change beam spacing (hole positions) | +0% | Just adjusting machine parameters, no extra charge |
| Change rack width (1200-3000mm) | +5-10% | Requires tooling adjustment |
| Change rack depth (800-1500mm) | +5-10% | Same as above, tooling adjustment |
| Change number of levels (2-8) | +0% | Just more or fewer beams |
| Custom color (any RAL) | +8-12% | Cleaning paint line + color switch |
| Custom steel thickness (1.5-3.0mm) | By weight | Material cost only, no extra labor |
| Logo printing / custom packaging | +3-5% | Silk screen + packaging design |
Key insight: About 50% of customization requests don't cost extra — they're just programming changes on the roll-forming machine. We'll usually give you 2-3 quotes side by side, showing where the cost difference comes from. You decide.
Who Should Customize — And Who Shouldn't
✅ Good candidates for custom racking
1. Non-standard warehouse shape
Columns, corners, equipment blocking straight rows
Standard racks always miss by a few centimeters
Custom layout can improve utilization by 15-25%
2. Non-standard pallet sizes
Pallet height > 1.5m (standard beam spacing too tight)
Pallet width > 1.2m (standard frame width not enough)
Pallet weight > 2000kg or
3. Mixed inventory (heavy + light, big + small)
Bottom levels: heavy duty (3000-4000kg), wide beam spacing
Top levels: light duty (1000-2000kg), tighter spacing for smaller boxes
Standard racking can't do this in one system
❌ Not a good fit for custom racking
1. Tight budget, less than 10 bays
Custom mold cost is too spread out at small quantities
Unit price could be 50%+ above standard
Recommendation: Look for standard sizes that are "close enough"
2. Temporary use (less than 6 months)
Custom racks are hard to resell (non-standard dimensions)
Better to rent standard racks (monthly rental $6-12/m²)
The Custom Process (4 Steps, 30-45 Days)
Step 1: Send a sketch (30 minutes)
No CAD needed. Hand-drawn + phone photo works:
Take photos (stand at entrance, show column positions)
Measure: length × width × height, mark column distances from walls
Tell us: pallet dimensions (L×W×H + weight), forklift type
Within 24 hours, we send a CAD layout showing how many bays fit, where, and estimated utilization rate.
Step 2: Approve design + get quote (1-3 days)
We offer 2-3 options, each with: price, lead time, space utilization. You pick one or send it back for revisions.
All design work is free during this stage. No commitment.
Step 3: Production (15-30 days)
10-30 bays: 15-20 days
30-100 bays: 20-30 days
Sample option (recommended): We build 1 bay as a sample first — ship by sea or air for you to inspect. Sample cost is deductible from the bulk order.
Step 4: Install and use
Installation guide: video + manual
If any dimension issue found: free revision (1 time, provided design was approved)
FAQ
Q: Warranty? What if something breaks? A: 1 year on structural issues (frame deformation, beam failure, weld cracks). Not covered: forklift damage, intentional damage. We have partner installers in Dubai, Riyadh, Mumbai, Singapore — 24-48 hour response. Critical spares (beams, safety locks, anchor bolts) kept in stock.
Q: Minimum order quantity? A: 10 bays minimum (1 bay = 1 frame + beams + bracing + anchor bolts + manual). Below 10, mold cost per unit is too high.
Q: What if I need to expand later? A: We keep your design on file. Order more any time — new racks match the original exactly (dimensions, hole pattern, color, coating).
Q: Can I get a sample first? A: Yes. Sample kit (1 bay = 1 frame + 2 beams). Sample cost is deductible from your first bulk order.
Q: Does custom racking take longer to deliver? A: Only if it requires significant tooling change. Simple changes (beam spacing, number of levels) don't add time. Color change or custom width adds 5-7 days.
Request a free layout drawing → Send your warehouse sketch to our contact form. We'll reply within 24 hours with a CAD proposal — no charge, no obligation.
P.S. Got columns in your warehouse? Odd corners? Strange dimensions? Send a sketch — we'll tell you honestly if custom racking makes sense, or recommend a standard option if it doesn't. Free advice, no sales pressure.
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