ONE PLATFORM FOR ALL REQUIREMENTS

Pallet Racking Solutions

The P90 platform from Dexion is the common foundation for wide aisle, narrow aisle and drive-in racking, for mobile racking and fully automated high bay warehouses up to 30 metres — scalable, expandable and automation-ready.

Capacity Up to 20% more storage

Future‑ready Manual to automated, one system

One partner Plan, build and operate

THE DEXION P90 PLATFORM

Industrial Pallet Racking Built To Maximise Warehouse Capacity & Support Growth

From conventional pallet storage to automation-ready warehouse infrastructure, Dexion pallet racking systems help businesses improve storage density, increase operational efficiency, and scale with changing logistics demands.

30 tonnes

Maximum bay load

5 tonnes

Maximum beam load

Up to 30m

Racking height possible

Up to 20%

Potential capacity gains through layout optimisation

Built For Growing Warehouse Operations

Dexion pallet racking systems are designed to help businesses maximise storage capacity, improve operational efficiency, and adapt to changing warehouse demand. From manual storage environments to automated distribution centres. All systems are designed on a common platform that simplifies expansion, supports automation integration and enables long-term warehouse adaptability.

Scalable Storage Infrastructure

Whether expanding pallet capacity, improving picking efficiency, or preparing for automation, Dexion's systems can be easily reconfigured and scaled as warehouse operations evolve.

Engineered For Long-Term Operational Performance

Manufactured for strength, consistency and long-term operational reliability across high-demand warehouse environments.

WAREHOUSE STORAGE SYSTEMS

What Is Pallet Racking & Why Is It Important?

Pallet racking is a warehouse storage infrastructure system that efficiently and safely organises palletised goods on a large scale, used in distribution centres, manufacturing, retail, and warehouse logistics. It maximises storage, improves stock access, and boosts operational flow. The right system enhances capacity, streamlines inventory, increases picking efficiency, and supports growth.

Maximise Warehouse Capacity

Pallet racking systems help businesses optimise warehouse space by increasing pallet positions without expanding the facility. They consist of an upright, beam, and bracing, forming the backbone of pallet operations.

Increase storage density
Improve use of vertical warehouse space
Reduce wasted floor area
Support warehouse expansion without relocation

Improve Operational Efficiency

Efficient pallet storage improves warehouse flow, pallet accessibility and inventory handling across fast-moving operations.

Faster pallet retrieval and replenishment
Improve stock organisation
Reduced warehouse congestion
Better picking and fulfillment efficiency

Supporting Scalable Warehouse Growth

Modern pallet racking systems are designed to adapt as warehouse operations evolve, supporting automation, new SKU profiles, and changing throughput demands.

Automation-ready configurations
Expandable storage infrastructure
Flexible warehouse layouts
Supports long-term operational planning

Choosing the right pallet racking system can significantly influence warehouse productivity, storage density, operational costs, and long-term logistics performance.

PALLET RACKING TYPES & APPLICATIONS

Which Pallet Racking Solution Fits Your Needs?

Not every warehouse needs the same solution. Describe your situation. We will recommend the right system type. Or choose directly from our racking variants.

P90 Pallet Racking

Designed for high-volume pallet storage with direct pallet accessibility and scalable warehouse expansion on a single engineered platform. The system can be easily retrofitted or automated without switching systems.

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Mobile Pallet Racking

Increase storage capacity by eliminating fixed aisles. Mobile racks open only where needed and adapt to changing storage requirements. Suitable for space-constrained warehouses and energy-sensitive environments.

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Pallet Shuttles

Store more pallets in less space with semi-automated high-density storage. Shuttle operations reduce forklift movements and improve throughput in repetitive storage processes.

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Explore Pallet Racking Systems for Every Warehouse Environment

From high-density storage to automation-ready warehouse systems, explore pallet racking solutions designed to support different operational requirements, throughput demands and storage strategies.

Wide Aisle Pallet Racking
Narrow Aisle Pallet Racking
Drive-In Pallet Racking
Drive-Through Pallet Racking
Pallet Flow Racking
Pullout Units
Multi-Tier Pallet Racking
Clad-Racks

View All Pallet Racking Solutions

CUSTOMER STORY

Pallet Racking Project Spotlight

Hear what our customers have to say about us

Mega Development

Building a Marvel of British Warehousing Ingenuity

The Range’s new 110,000m² Gateway 14 distribution centre is one of the largest in southeast England, supporting 210+ stores and e-commerce.

Partnering with Dexion, it has 145,000 pallet positions, two mezzanine floors with 16,500m² of shelving, and zones for high-value, dangerous, and seasonal goods, creating a high-density hub.

It streamlines operations, supports multichannel growth, and ensures agility in peak periods. Delivered through a phased handover, it features advanced safety features and space for 1,000 new employees from the local area. It’s a core part of The Range’s supply chain, designed to grow and adapt.

110,000m² FLOOR SPACE

145,000 PALLET POSITIONS

1,000 NEW JOBS CREATED

Retail E-commerce Home & Leisure

Read the full customer story

PROJECT MANAGEMENT

Supporting Your Warehouse Project From Concept to Completion

Choosing the right intralogistics solution is not simply a matter of selecting individual products. It is a long-term business decision. Your investment must remain scalable, flexible and high-performing for years to come.

Consulting & Planning

Detailed recording of all functional and technical requirements. We capture your existing processes, identify optimisation potential and take growth prospects and safety standards into account from the outset.

Concept & System Development

We translate the analysis results into a modular system design: technology-neutral interface concepts, retrofittability as an integral component and full consideration of future automation potential.

Proposal Creation

Every proposal is supported by detailed technical assessments and a feasibility evaluation. Clear presentation of scope, timeline and cost structure, without hidden surprises. Decision-ready information.

Manufacturing, Installation & Commissioning

Precision industrial manufacturing in our own plants. Professional installation by experienced installation teams on site. Systematic testing, acceptance and complete documentation.

Operations

Reliable system operation and performance monitoring. Certified racking inspections in accordance with EN 15635, conducted by our own inspectors, with comprehensive documentation and recommendations for proactive measures.

Service & Development

Regular maintenance, performance assurance and strategic development. Adaptation and expansion of existing systems (retrofit). Long-term protection of your investment through professional services.

SYSTEM DERIVATIVES

High-Density Storage Solutions Supported By P90

Beyond conventional adjustable pallet racking, the P90 platform supports a range of high-density and gravity-fed storage configurations designed to improve storage efficiency, stock rotation and warehouse throughput.

Push-back Racking

High-density storage using inclined carts or rails to store multiple pallets within a single lane. Ideal for LIFO inventory management and high-volume SKU storage.

Pallet Live Storage

Gravity-fed pallet flow system that supports FIFO stock rotation while reducing forklift travel and improving throughput.

Carton Flow Systems

Gravity-fed carton and tote storage designed to improve picking efficiency and support high-volume fulfilment operations.

Shuttle Storage Systems

Semi-automated pallet storage solution that increases storage density while reducing forklift movements within storage lanes.

PALLET RACKING BEAM TYPES

Beams: The Right Profile For Any Load & Application

Beam selection directly influences load capacity, pallet support, warehouse durability and compatibility with different storage applications. Our beams are engineered to support everything from standard pallet storage to highly customised and automated warehouse environments.

Box Beam

Box beams are the standard load-bearing solution within the P90 system, designed for a wide range of warehouse conditions. Available as hot-dip galvanised or painted, they offer a flexible combination of corrosion protection, durability and surface finish depending on the operating environment.

Galvanised option for long-term corrosion protection
Painted option in RAL colours for visibility and layout structuring
Additional coatings available for demanding conditions
Designed for long-term durability across applications
Beam heights from 60mm to 160mm

Open Beam

Open beams are designed for applications where pallet loads are not directly supported by standard beam geometry. They enable the integration of decking, support bars and special load carriers, creating a flexible interface between the racking structure and the stored goods.

Open profile for integration of decking and support elements
Suitable for non-standard pallets and special load carriers
Flexible configuration within the P90 system
Enables customised load support solutions
Beam heights: 50mm or 75mm

I-Beam Silverline

Galvanised I-profile beam designed as an efficient load-bearing solution for specific applications within the P90 system. The geometry enables a cost-conscious alternative for defined load scenarios while maintaining structural stability.

Economical beam solution for defined load scenarios
I‑profile geometry optimised for distributed loads
Optimised beam geometry for efficient load distribution
Suitable for applications with predictable load conditions
Beam heights: 100mm, 125mm, 140mm

Special and custom profile variants

Step Beam

For P90 only with adapted connectors; rarely used in standard P90 applications

Sigma Beam

Racking with chipboard and steel decking

IPE Beam

Very heavy special constructions

The beam is the load-bearing element between the frames. Not every load requires the same solution. Dexion manufactures all beam types in-house and offers the right profile for every application. Beam lengths can be configured from 500 mm to 5,000 mm, subject to structural verification.

P90 ACCESSORIES

Everything Your Pallet Racking Needs To Perform Safely

Accessories, protection systems, and retrofit solutions designed to improve safety, maximise storage efficiency and adapt your racking to operational demands.

Upright Protector

Flexible impact element for racking uprights. Absorbs impact energy during forklift operation and protects the supporting structure from permanent damage. Easy to install and replace.

Anti-Collapse System

Prevents pallets and goods from falling out of the racking bay - to the rear and to the side. Retrofittable as a mesh panel or a net system, without affecting racking statics.

Impact Protection Bollard

Protection for exposed areas such as passageways, wall corners and building gates against vehicle impact. Absorbs impact forces and prevents structural damage to the building and infrastructure.

Customised Protection

We support your system by creating bespoke safety accessories to fit varying needs. Including custom upright protectors cut to the correct size.

Wire Mesh Decking

Protection against falling objects. Standard for systems with aisle operation and in public areas.

Steel Decking / Panels

High-quality steel decking creates additional storage area for containers, small packs and loose goods.

Pallet Support Bars

Supports pallets where the middle bottom board runs parallel to the racking beam, e.g. for cross-stacking.

Sprinkler Protection Brackets

Available in two sizes, depending on load requirements. Standards-compliant for fire protection systems.

Load Notice Signs

Display all load data for the racking system. Mandatory under EN 15635, assigned to the respective configuration.

Racking Labels

Self-adhesive or magnetic label holders for beams and decking. Also available as a sign and labelling system.

Shelving Dividers

Helps to keep your stock separated and compliant with sprinkler and fire safety standards.

PALLET RACKING PROJECTS

New Build, Expansion or Modernisation: What Is The Right Choice For Your Warehouse?

Many projects start with the wrong question. Often an expansion or modernisation is the more economical decision.

Retrofit / Modernisation

Existing system at performance limits or with optimisation potential.

Moderate investment
Weeks to months project duration
Minimal disruption to operations (in phases)
ROI: 6–18 months
Low resource consumption

Warehouse Expansion

More capacity or new storage variants within the existing system.

Low to moderate investment
Days to weeks project duration
Minimal disruption to operations
Fast ROI
Asset life extended

New Warehouse

Complete repositioning or site relocation.

Very high investment
12–36 months project duration
Significant disruption to operations
Long-term ROI
High resource consumption

P90 SERVICE & AFTERSALES

Extended Support For Your Investment

Availability instead of downtime. Maintenance, inspection and support directly from the manufacturer.

Maintenance Packages

Basic, Standard, Premium packages
Planned maintenance with service report
Remote support and hotline included, package dependent

Inspections and Compliance

Rack inspection to EN 15635
Inspections included in packages
Accident prevention testing, package dependent

Support and Response

Technical hotline for customers
Remote support via TeamViewer Assist AR
On site response is typically within 24 hours

Spare Parts and Retrofit

Standard spare parts stocked
On site spare parts packages reduce downtime
Retrofit and modernisation extend system life

FOUNDED 1937 — INVENTED 1947

The Pioneers of Modern Racking Solutions

"Dexion" comes from Ancient Greek and means "to do the right thing". This commitment was cast in steel in 1947, and it still shapes how we build racking to this day.

1937

Founded in London

Demetrius Comino, an Australian of Greek descent, founded Dexion in London. Driven by a desire for a better storage system for his printing business, he invented the modern racking system.

1947

Dexion Slotted Angle Invention

Comino developed the first perforated, bolted steel profile: the "Slotted Angle". Lighter than wood, more stable, and quick to assemble and disassemble. The cornerstone of all flexible racking systems.

Today

Part of the Gonvarri Material Handling Group

Dexion is part of a European family of brands today, with roots dating back to 1856. Own manufacturing in Laubach (Germany) and Rasnov (Romania). Engineering, manufacturing and installation from a single source.

MANUFACTURING

Manufacturing Expertise Makes The Difference

We go beyond just manufacturing racking systems. We provide measurable, standards-compliant, and dependable intralogistics performance that can be planned with confidence. Our engineering standards, digital planning, and industrialised production processes help eliminate risks.

Variant Flexibility

Tailored customer solutions on a common platform basis, standardised or individually engineered.

Industrial Quality

Smart manufacturing at competitive prices: industrialised processes, reproducible quality, full control.

Industry Standards Compliant

Testing to SEMA, FEM, CE, EN, ISO. Technical values from our own test laboratory, not from assumptions.

Automation-ready

All systems are designed to be automation-capable from the outset, for manual to fully automated operating models.

MANUFACTURING EXPERTISE

We Deliver Reliable Performance

Engineering standards and industrialised production reduce risk and create predictable outcomes.

Reliability is not a promise. It is engineered into every step.

We don't just manufacture shelving systems, we deliver verifiable, standards-compliant and reliably predictable intralogistics performance.

Our engineering standards, digital planning and our industrialised production system eliminate risks for the customer and ensure long-term reliability.

Full traceability Mother coil

Tested specs Lab verified

Standards SEMA FEM CE EN ISO

Verified Engineering

Certified quality ensures compliance.

Build to Order

Standardised, fast and reliable. For defined requirements with short delivery times.

Standardised modules
High repeatability
Short delivery times

Build to Engineer

Individual, precise and integrated. For complex requirements and system integrations.

Customer-specific design
Individual structural engineering
System integration and special solutions

A Common Foundation

Different project logics with consistent quality. Our manufacturing makes project success plannable.

Same quality basis for all projects
Scalable without changing systems

Technical Master Platform

A central Dexion engineering database and in-house testing ensure consistent and reliable system performance.

Manufacturing Processes

Roll forming, fully automated welding, steel construction and surface treatment: industrialised processes for reproducible quality and delivery reliability.

Technical Design

Global applicability through seismic and fire protection compliance. Full traceability of components back to the mother coil.

Digital Engineering

CAD and FEM integration for precise planning. Intelligent product logic instead of pure geometry. Automatic collision and plausibility checking.

WAREHOUSE AUTOMATION

Built For Automation. Ready For Evolution

The P90 platform creates a stable infrastructure layer for future automation investments.

Robotic Picking

Rack structures designed for robotic and hybrid picking environments. Ready for scalable automation from manual to autonomous operations.

Autonomous Material Flow

Infrastructure prepared for autonomous transport systems, intelligent routing and high-efficiency material flow operations.

Automated Storage Systems

Engineered for integration with high-bay automation, shuttle systems and scalable automated storage technologies.

Warehouse Intelligence & Software

Integrated warehouse intelligence enabling real-time visibility, process orchestration and seamless connectivity across automated operations.

Tell us about your pallet racking project

Whether you plan a new warehouse, expand your existing system or assess current infrastructure, we respond within four hours with a concrete next step. No sales pitch. No pressure. Just a clear and honest assessment based on your requirements.

4h response time on working days
Our own engineering team
Free initial consultation
References from your industry
Own R&D
Own production facilities in Europe

SUSTAINABILITY

Leading In Quality, Certifications & Responsibility

Reliability in design, manufacturing and execution, combined with a clear commitment to sustainable development as part of the Gonvarri Material Handling Group.

Proof

EcoVadis Gold certification (Jun 2025) of the Gonvarri Material Handling Group. Evaluates environment, social, ethics and sustainable procurement. Top 5% of all companies assessed worldwide.

Own manufacturing

Production in Laubach, Germany and Rasnov, Romania ensures short supply chains, consistent quality and full control over specifications, including special dimensions and spare parts.

Long-term efficiency

Sustainability is evident throughout the entire life cycle of a storage system. The P90 platform enables expansion, retrofitting, and automation without the need to replace the system. Existing structures remain usable and do not need to be replaced.

Safe operation and compliance

Design in compliance with standards and certified testing processes ensure long-term operation and reduce risks to people, infrastructure, and businesses. Regular inspections and verified structural analysis prevent damage and unplanned outages.

FAQ

Frequently Asked Questions About P90 Pallet Racking

The most important questions on the way to the right warehouse solution.

What do pallet racking projects cost?

Pallet racking is planned on a project-specific basis. There are no fixed prices. The decisive factors are the number of pallet locations, storage height, shelf loads, access system and level of configuration.

For an initial assessment, we need the floor area, approximate number of pallet locations and goods structure. We respond within four hours on working days with a concrete next step.

How long does a pallet racking installation take?

From enquiry to operational system, a standard project typically takes 8 to 16 weeks, depending on complexity, building permits (if required) and installation scheduling. For expansions of existing systems, it is often significantly faster.

Can I expand or modernise my existing racking?

In most cases, yes. The prerequisite is that the existing system complies with standards. Ideally, you have pallet racks with the P90 profile. These can generally be expanded without any problems. In the existing warehouse, Dexion pallet racks can also be installed as separate rack aisles. Integration with rack systems from other suppliers is not possible, as different profiles and beams are used. We will assess this as part of a facility analysis and identify which expansion and modernization options are feasible and economically viable.

What happens if my warehouse is to be automated in the future?

The P90 platform is designed exactly for this case. Many automation solutions, from pallet shuttle to fully automated high bay warehouses, are built on the P90 basis. You do not need to introduce a new system, but can upgrade step by step. This protects your investment.The combination with AGV's or AMR's is also possible.

How often should pallet racking inspections be carried out?

According to EN 15635, an annual inspection by qualified personnel is mandatory. In addition, the operator must conduct ongoing visual inspections. Dexion offers certified racking inspections that include comprehensive documentation and specific recommendations for action.

What pallet racking is best for e-commerce fulfilment?

The best pallet racking system for e-commerce fulfilment depends on order volumes, SKU variety, picking methods and warehouse throughput requirements.

Warehouses handling high SKU counts and fast-moving inventory often benefit from selective pallet racking systems that provide direct access to every pallet location and support efficient picking operations. High-density systems, such as narrow aisle or shuttle-based storage, may also help increase capacity while maintaining operational efficiency.

For fast-growing e-commerce operations, pallet racking systems should also support scalability, fast stock accessibility and future integration with automated systems to accommodate increasing demands.

Does Dexion install the racking itself?

Dexion works with certified, audited, and trained installation companies throughout Europe.

Can pallet racking be integrated into existing warehouses?

Yes. Modern pallet racking systems can be integrated into existing warehouse environments to increase storage capacity, improve operational flow, and support changing business requirements without requiring a complete facility rebuild.

Retrofit pallet racking projects can include warehouse reconfiguration, capacity expansion, aisle optimisation, safety upgrades or preparation for future automation. The right solution depends on factors such as building dimensions, floor loading, stock profile, handling equipment and operational throughput requirements.

Scalable pallet racking systems also allow businesses to expand or adapt storage layouts as warehouse operations evolve over time.

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