Pushback Racking FAQs

Everything you need to know about Pushback Racking

What are the typical lane depths available for pushback racking systems?

Pushback racking systems can typically be configured from 2 to 6 pallets deep, depending on the load weight, pallet type, and desired storage density. Deeper lanes help maximize warehouse space while maintaining efficient access to stored goods.

How is the rail slope in a pushback racking system determined, and why does it matter?

The pushback racking system utilizes a slope of 3/8″ per foot, or just a little less than two degrees. For example, a standard 4 deep lane for 48 deep pallets would have 6″ of slope. This slope ensures that empty carts will always return to the front of the lane if accidentally pushed back by the operator. In most cases the total slope is less than the lift clearance above the pallet at the load end, and therefore, does not affect the number of storage levels.

We can also reduce the slope if you have a special requirement. Because our wheel rolls on a low friction tube compared to a rough C channel or I-beam, lower slope is not an issue.

What types of forklifts are compatible with pushback racking systems?

Pushback racking can be used with most standard forklifts, including counterbalance, reach, and swing reach trucks. The system is designed for flexibility, so no specialized equipment is required for standard operations.

How wide should aisles be for efficient pushback racking operation?

Aisles should provide enough clearance for the operator to square the forklift directly to the rack face—typically 6 inches more than the truck manufacturer’s minimum aisle requirement. Proper aisle design improves safety and load handling efficiency.

How much push force is typically required to load pallets in pushback racking?

The force required to push back pallets is usually around 4% of the total load weight. For example, a 2,000 lb pallet in a 6-deep system requires about 400 lbs of push force—well within the range of most lift trucks.

What are the space requirements for pushback racking solutions?

The following are general rules of thumb: 

Vertical level to level of beams 
For 2, 3 & 4 deep pushback- pallet height + 12″
For 5 & 6 deep pushback – pallet height + 14″

Rack depth
(# of pallets deep X (pallet depth + 2″)) + 2″
(i.e., 102″, 152″, 202″, 252″, and 302″ for a 48″ deep pallet for 2/3/4/5/6 deep)

Beam Width
Single wide bays – pallet + 8″
Double wide bays – (pallet + 8″) x2

Can pushback racking be used in cold storage or freezer environments?

Pushback racking performs reliably in a wide range of temperatures—from +50°C to -60°C. It’s well-suited for cold storage, food and beverage facilities, and blast freezer environments.

How difficult is it to load and unload from 3D pushback racks?

Experience has shown that most operators are completely efficient within a half day. Many operators state that pushback is easier to load and unload than standard pallet rack. Operating instructions are sent with each system.

What kind of maintenance or inspections are required for pushback racking systems?

Pushback racking requires minimal maintenance. Bearings are permanently lubricated, and periodic visual inspections are recommended to ensure components remain clean and aligned for long-term safety and performance.

Can you achieve FIFO with pushback?

Contrary to popular belief, it is easy to achieve first-in first-out with pushback racking. The key is to configure your system to ensure that each product (SKU) utilizes multiple lanes. If each product has three or four lanes of pushback, the operator simply ships out the oldest lane first. See our FIFO Page.

How does 3D pushback compare to the competition?

3D has one of the lowest profiles in the market. Our 5 and 6 deep lanes are half the height of most other systems. This height difference results in extra lift clearance and future load height flexibility it may also allow an extra pallet level.

Our pushback racking system is equipped with several key safety features that others do not offer – linked carts, lane full indicators, pallet stops and cart lift-out protectors are all standard features.

3D assembles the carts before we ship them, including attaching the shafts and wheels to the carts at our facility. We also only mount to the front and rear beams and do not need to mount to the internal beams. This results in faster and less expensive installations.

We have some of the strongest wheels and shafts in the industry the wheels are rated at 1,400 lbs and the 5/8″ solid steel shafts that are welded to the cart.

We offer 2 to 6 deep pushback racking to best suit the layout and application. Many others manufacture only 2 and/or 3 deep lanes. We also can produce many non-standard designs depending on the application, such as steel sheet or mesh covered carts, heavy duty lanes and level carts.