When floor space is at a premium but stock needs keep growing, smart storage becomes a game-changer. Whether you’re dealing with heavy pallets of cement or rows of smaller, high-turnover items, the right racking and shelving can transform how your builders merchants branch operates.
In this guide, we’ll unpack clever ways to maximise SKUs per square metre, boost visibility, and ensure your storage setup is both safe and efficient. We’ll also spotlight some real-world examples and dive into load ratings and UK safety standards — so you can be confident your setup ticks every box.
🏗️ Why Storage Matters for Builders Merchants
Builders merchants are unique. You’re juggling bulky materials like timber and plasterboard with smaller fittings, adhesives, and fasteners — often in the same space.
Poor storage layouts:
- Limit product range
- Slow down order picking
- Increase the risk of damage or injury
- Make stock hard to find and even harder to manage
That’s where clever racking and shelving systems come in — they help you stock more SKUs, use vertical space better, and keep everything visible and accessible.
🧱 What’s the Difference Between Racking & Shelving?
Understanding the difference is key to designing an efficient layout.
These are designed for bulk storage, especially for pallets and heavier goods. Think:
- Adjustable Pallet Racking – Ideal for high-density stock in vertical space
- Cantilever Racking – Great for long items like timber, pipes, or sheet materials
- Drive-In Racking – Perfect for high-turnover, same-SKU inventory
They’re typically loaded by forklift and built to carry heavy weights, so load ratings and structural integrity are crucial.
Shelving is geared towards smaller, hand-picked items. For example:
- Steel Shelving Units – Tough, modular, and great for everything from screws to paint tins
- Long Span Shelving – A hybrid option for slightly heavier stock, like boxed tools
- Adjustable Shelving – Keeps things flexible when SKUs change regularly
These are usually manually loaded and accessed — speed, visibility, and organisation are the name of the game.
Pro Tip: Combining both systems gives you the best of both worlds — high-capacity storage with easy access to fast-moving lines.
📈 How to Increase SKUs Per Square Metre
The golden metric for builders merchants is how many SKUs you can fit in a limited space without it feeling like a stockroom maze.
Here’s how to maximise every square metre:
1. Go Vertical
Use racking systems that stack up to 5 or 6 metres high. Even with standard pallet racking, you can double or triple your floor space by building up, not out.
2. Narrow Aisles, Wide Benefits
Switch to narrow aisle racking and use guided handling equipment like VNA (Very Narrow Aisle) forklifts. This saves horizontal space without compromising access.
3. Zoning & Labelling
Group stock by category, product type or weight class. This makes picking faster and helps avoid overstocking or duplication.
4. Adjustable Shelving
Custom-fit your shelving to match SKU sizes — no wasted gaps, no crammed shelves.
5. Mezzanine Floors
If you’ve got the ceiling height, a mezzanine floor can double your usable space — think top floor for storage, bottom floor for customer-facing displays or order prep.
🧐 Visibility Is Everything
If your staff can’t find it, it might as well be out of stock.
Builders merchants shelving should prioritise:
- Open fronts or bin front shelves for quick scanning
- Clear signage and shelf-edge labels
- Integrated lighting for darker corners or deeper shelves
Stock visibility isn’t just about ease — it helps with:
- Inventory checks
- Replenishment cycles
- Reduced picking errors
When combined with a good stock control system (digital or manual), your racking and shelving layout becomes a powerful part of your logistics flow.
🔐 Safety First: Load Ratings & UK Guidelines
Builders merchants carry serious weight — literally. That’s why understanding load ratings is non-negotiable.
Load Ratings to Know:
- Uniform Distributed Load (UDL) – The total load spread evenly across a shelf
- Point Load Capacity – Localised loads (e.g., a heavy bag of cement at one corner)
- Beam Levels & Frame Loads – Critical in racking systems
Each racking bay should have clearly displayed load notices, as required by UK HSE regulations.
Safety Best Practices:
- Regular inspections (at least annually or after impact)
- Load distribution checks
- Staff training for manual handling and safe stacking
- Safe access – especially with ladders, lifts, or forklifts
If you’re not sure about compliance, a professional racking inspection or storage system audit from a trusted provider like Total Interiors Direct can save time and risk down the line.
🔧 How Total Interiors Direct Can Help
We’re not just suppliers — we’re problem solvers.
From design consultations to full installation, Total Interiors Direct works closely with UK builders merchants to:
- Optimise warehouse layouts
- Improve SKU density
- Ensure health & safety compliance
- Reduce stock picking time
Whether you’re refitting an old space or starting from scratch, our team will tailor your builders merchants racking system or shelving to match your specific product mix and business flow.
Want a no-obligation storage audit? Contact our team today and we’ll help you turn that cluttered corner into your most productive square metre.
🙋 Frequently Asked Questions
How do I know what load rating I need for my shelves?
We calculate this based on your products’ weight and how you stack them. It’s best to get a professional assessment to ensure safety and compliance.
Can I combine shelving and racking in the same area?
Absolutely! This hybrid approach is common and efficient, especially when SKUs vary widely in size and turnover.
Do you offer custom-built racking systems?
Yes, we design bespoke systems tailored to your space and product types — from timber to tools to plumbing supplies.
Is planning permission needed for mezzanine floors?
Not always, but building regulations usually apply. We’ll guide you through the entire process.
🔚 Wrapping It All Up
The key to a smarter, more efficient builders merchants store isn’t just stocking more — it’s about storing better. With the right racking and shelving systems, you can:
✅ Maximise your SKU count per square metre
✅ Boost picking speed and stock visibility
✅ Maintain full safety compliance
✅ Future-proof your space as product lines grow
Total Interiors Direct is here to make that happen — efficiently, affordably, and with expert care.
Let’s rethink your storage space — get in touch and let us show you what’s possible.
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