Storage needs never stop growing—but your floor plan probably isn't. When you're working with fixed square footage and rising inventory demands, optimizing vertical space is the most cost-effective way to grow. Pallet rack systems allow facilities to scale intelligently by combining structural strength with layout flexibility. And that flexibility starts with how you build: using starter and add-on units.
More Inventory, Same Footprint
If your facility already has pallet racking installed, expanding it doesn’t mean starting from scratch. Add-on units are designed specifically for this purpose. By attaching directly to your existing upright frames, they extend your storage row with less material and lower installation time.
This is a smart move when shifting seasonal inventory, expanding picking zones, or consolidating SKUs into tighter rows. Instead of buying another full starter unit—and wasting both money and space—an adder gets the job done faster and more efficiently.
Already Have Racking? Add to It Efficiently
Starter and adder units are the foundation of any scalable pallet rack system. A starter unit includes two uprights and can stand independently. An add-on (or adder) unit shares an upright with an adjacent section. This simple structural distinction can have a huge impact on your budget and your floorplan.
By designing around add-on units, facilities can minimize steel usage and avoid unnecessary duplication of vertical supports. This not only reduces upfront material costs but also frees up aisle space, supports tighter configurations, and allows you to grow your system without completely redesigning it. Adders are particularly useful when you're expanding row by row, integrating new product lines, or reconfiguring zones within a warehouse.
Why Planning Your Layout Matters
When designing a racking system, the most efficient setup isn’t always the most obvious. Factoring in starter/add-on configurations from the beginning ensures you're not overbuilding your infrastructure. It also improves forklift maneuverability, maintains safe aisle spacing, and avoids costly teardown if changes are needed later.
We work with facilities across manufacturing, warehousing, and fulfillment to build racking systems that are strong, strategic and fit well into many applications.
Common Mistakes to Avoid with Pallet Rack Expansion
Even experienced operations teams can run into avoidable issues when scaling rack systems. Some of the most common include ordering multiple starter units when adders would suffice, misjudging height and depth requirements, or forgetting to account for clearance needed by lift equipment.
Other mistakes include installing incompatible rack types next to each other or failing to match weight capacities across expanded rows. Each of these can lead to delays, safety concerns, or extra costs.
Need Help Quoting or Planning?
Because pallet racks vary by size, material, and load capacity, it’s important to get a tailored quote based on your needs. At StoreMoreStore, we design systems that grow with you, and that includes helping you avoid overbuying parts you don’t need.
Contact us to discuss your layout, your current infrastructure, and how starter and add-on units can simplify your next expansion.