Pallet racking vs rivet racking
If you're kitting out a warehouse or stockroom, these two keep coming up — and it's not always obvious which one you need. The short version: pallet racking is for bulk palletised stock moved by forklift; rivet racking is for goods your team picks by hand. But there's more to it than that.
| Pallet Racking | Rivet Racking (Boltless) |
|---|---|
| Loaded by forklift | Loaded by hand |
| Stores full pallets | Stores individual items and cartons |
| Very high loads 1,000+ kg/pallet | Up to 600 kg UDL per shelf |
| Can reach 10+ metres high | Typically, up to 3–4 metres high |
| Higher cost and complexity | Lower cost, faster to install |
| Requires MHE to access stock | Staff pick directly by hand |
| Anchored to the floor, semi-permanent | Boltless, easy to move and reconfigure |
What is pallet racking?
Pallet racking is a heavy-duty steel storage system designed to hold palletised goods that are already stacked on wooden or plastic pallets, and loaded using a forklift truck, reach truck, or other mechanical handling equipment (MHE). It is the backbone of most UK warehouses, distribution centres, and fulfilment operations.
How it's built
A standard pallet racking bay consists of two vertical steel upright frames connected by horizontal load beams. Pallets straddle the front and rear beams at each level. There is no solid shelf surface; the pallet itself spans the gap. Wire mesh decking can be added between beams for safety or to allow hand-picking at lower levels.
Load capacity
Pallet racking is engineered for serious weight. Individual pallet loads of 1,000 kg are common, and heavier configurations are standard in food, drink, and manufacturing environments. Bay loads can run to tens of thousands of kilograms across multiple levels.
Heights and configuration
Systems can be built to the full internal height of a warehouse, 10 metres and above in taller buildings. Standard configurations include wide-aisle (the most common, giving forklift access to every pallet), narrow-aisle, double-deep, drive-in, and push-back racking, each suited to different storage density and access requirements.
Installation and compliance
Pallet racking must be floor-anchored and installed to SEMA (Storage Equipment Manufacturers' Association) standards. Annual inspection by a SEMA-approved Rack Inspector (SARI) is strongly recommended, and a Person Responsible for Racking Safety (PRRS) should be appointed on site. Load notices must be displayed on every bay.
What is rivet racking?
Rivet racking (also known as boltless shelving, rivet shelving, or boltless racking) is a hand-loaded storage system for individually picked goods. The name comes from its construction method: beams lock into upright posts using a rivet-and-keyhole system, with no nuts, bolts, or specialist tools required. Assembly and reconfiguration are fast, typically using only a rubber mallet.
How it's built
Rivet racking uses steel angle or channel uprights with regularly spaced keyhole slots. Beams drop into these slots and are locked in place by the rivet mechanism. The shelf surface (usually chipboard or wire mesh decking) sits across the beams. Like longspan shelving, starter bays can be extended with add-on bays that share a common upright.
Load capacity
Heavy-duty rivet racking typically supports 400–600 kg UDL per shelf and up to 2,800 kg per bay, depending on configuration. This puts it in a similar bracket to longspan shelving, though the two systems use different connection mechanisms and component profiles.
Heights and configuration
Most rivet racking is used at heights accessible by staff on foot or with a small ladder or order-picking truck, typically up to 3–4 metres. Because it is boltless and lightweight, it is one of the most flexible warehouse racking systems available: bays can be reconfigured, relocated, or expanded quickly as storage needs change.
Boltless shelving vs rivet racking: Is there a difference?
In UK usage, the terms are interchangeable. Boltless shelving and rivet racking describe the same type of system, which is a hand-loaded, tool-free steel shelving structure. Some suppliers use 'rivet racking' to emphasise heavier-duty configurations and 'boltless shelving' for lighter-duty office or retail applications, but there is no firm industry distinction.
Key differences explained
How stock is accessed
This is the one that really matters. Pallet racking is built around the forklift; entire pallets go in and come out by machine. Rivet racking is built around your team; someone walks up and picks what they need. If your staff are reaching in and grabbing individual items, rivet racking will almost always work better.
Load capacity
Pallet racking handles far heavier loads. A single pallet-level beam pair might be rated for 2,000–4,000 kg or more. Rivet racking's 400–600 kg UDL per shelf is substantial for a hand-loaded system, but it is not designed to take pallet-level point loads. Never attempt to load rivet racking with a forklift. The uprights are not designed for that type of impact loading, and the system will fail.
Height
Pallet racking can effectively use the full height of a warehouse, making it the right choice when vertical space is the primary asset to exploit. Rivet racking is generally limited to heights accessible without heavy machinery, though it can be incorporated into multi-tier mezzanine structures for greater vertical use.
Cost and installation
Rivet racking is significantly cheaper per bay than pallet racking and can be assembled by site staff without specialist contractors. Pallet racking involves higher material costs, professional installation, floor anchoring, and ongoing inspection requirements. For smaller operations or spaces with lower throughput, rivet racking offers much better value.
Flexibility
Rivet racking wins here, no contest. You can pull a bay apart and rebuild it in a different configuration in minutes. Pallet racking, once it's bolted to the floor, is pretty much staying put. If your business is growing or your stock profile changes seasonally, that flexibility is worth a lot.
Safety and compliance
Both systems require proper load notices and regular inspection. Pallet racking carries stricter compliance requirements given the scale of loads and the use of heavy machinery. Rivet racking is lower risk by classification but still requires correct installation, no overloading, and periodic checks, particularly in environments where pallet trucks or other MHE pass nearby.
When to use pallet racking
Pallet racking is the right choice when:
- Your stock arrives and is stored on pallets
- You use forklifts, reach trucks, or other MHE to move goods
- You need to maximise vertical storage in a tall warehouse
- You store large volumes of a relatively small number of SKUs
- Your loads exceed what a hand-loaded system can safely support
- You need a high-density solution such as drive-in or push-back racking
When to use rivet racking
Rivet racking is the right choice when:
- Staff pick individual items by hand rather than moving full pallets
- You store a wide range of SKUs in smaller quantities
- You need a flexible system that can be reconfigured as stock profiles change
- Budget is a priority, and you need a cost-effective solution quickly
- You're fitting out a stockroom, workshop, trade counter, or archive
- You want a system that staff can assemble and adjust without specialist contractors
Can you use both in the same warehouse?
Yes, and many UK warehouses do exactly this. A common layout uses pallet racking for bulk reserve stock in the main warehouse area, with rivet racking or longspan shelving bays in the pick face or mezzanine areas where staff are working at floor level. This hybrid approach gives you the density of pallet racking where you need it and the accessibility of boltless shelving where staff are actively picking orders.
Pallet racking systems can also be fitted with wire mesh decking and used for hand-picked stock at the lower levels, a practical way to use the bottom bays of a racking run that can't easily be accessed by forklift.
Quick-reference specifications
| Pallet Racking | Rivet Racking (Boltless) | |
|---|---|---|
| Loading method | Forklift / MHE | By hand |
| Typical shelf/level load | 1,000–4,000+ kg | 400–600 kg UDL |
| Typical bay load | Up to 40,000 kg (heavy systems) | Up to 2,800 kg |
| Typical height range | Up to 10+ metres | Up to 3–4 metres |
| Assembly | Professional installation required | Boltless: rubber mallet only |
| Floor anchoring | Required | Recommended above 2.5 m |
| Reconfiguration | Difficult once installed | Fast and easy |
| SEMA inspection | Annual SARI inspection recommended | Risk-based: regular in-house checks |
| Relative cost | Higher | Lower |
| Best environment | Warehouse / distribution centre | Stockroom / workshop / pick face |
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Frequently asked questions
Similar, but not quite the same. Longspan shelving tends to use wider bays (up to 2,700 mm) and heavier beam profiles. Rivet racking typically comes in narrower widths and uses a rivet-and-keyhole connection rather than a clip system. In practice, a lot of suppliers use the terms interchangeably, but if you're unsure, check the bay width and load rating rather than the name.
No. Rivet racking is engineered for hand-loaded items only. Placing a loaded pallet on rivet racking (even a light one) risks structural failure. The uprights are not designed for the point loads and lateral forces involved in forklift placement. If you need to store pallets, use a properly rated pallet racking system.
Generally, no, for standard racking within an existing building. However, very large or high installations may require structural calculations and approval, particularly if they affect fire safety, sprinkler coverage, or building load limits. Always consult your building owner or facilities manager for significant installations.
There is no statutory requirement for a formal annual inspection of rivet racking (unlike pallet racking, where a SARI inspection is strongly recommended). However, you should carry out regular in-house visual checks, keep a record of any damage, and ensure the system is never overloaded. In higher-risk environments (where MHE passes nearby), more frequent checks are advisable.
A starter bay is a complete, freestanding unit with four uprights. An extension bay shares one pair of uprights with the adjacent bay, reducing cost and floor footprint. When building a run of racking, you need one starter bay and as many extension bays as required.
