Racking maintenance is the most common job an aerial platform is bought for, and it is also the job where the wrong machine is bought most often. The work is repetitive, the access is usually from an aisle, and the height is rarely the only constraint. This guide sets out what actually decides the machine, and where each of the three common choices stops working.
What racking maintenance actually involves
Racking work is a mix of four tasks: inspecting and repairing damaged beams and uprights, replacing sprinkler heads and pipework above the racking, changing lighting and signage, and cleaning or painting the structure. Most of it happens along the face of the racking at a consistent height, which is why a machine that can drive itself along the aisle beats one that has to be repositioned from the ground.
The three measurements that decide the machine
- The height of the top beam plus working clearance. Measure to the highest point hands must reach, not to the top of the racking frame.
- The aisle width, and whether it is clear all the way along. Narrow aisles favour a scissor lift or a mast lift; a boom lift needs room to set its base.
- Where the work point sits relative to the aisle. If the platform has to reach over the top of the racking, or work on the far side of a beam, the machine needs a jib or an articulating boom.
Scissor lift, articulated boom or mast lift
| Self-propelled scissor lift | Articulated boom lift | Mast lift with jib | |
|---|---|---|---|
| Working height | 8 m to 14 m | 16.58 m to 22 m | 11.2 m |
| Platform | 2.27 x 1.12 m with 0.9 m extension | 1.83 x 0.76 m, or 2.4 x 0.9 m | 0.62 x 0.87 m |
| Rated load | 320 kg to 450 kg | 250 kg to 350 kg | 200 kg |
| Machine width | 0.85 m to 1.22 m | 2.32 m to 2.45 m | 1.0 m |
| Machine weight | 2,450 kg to 3,570 kg | 6,850 kg to 9,000 kg | 2,950 kg |
| Reaches over racking | Extension deck only, 0.9 m | Yes, 7.86 m to 8.54 m up and over | Yes, 3 m reach, 7.89 m up and over |
| Best for | Work along the racking face | Work above and behind the racking | High work in narrow aisles |
What we see in practice
Most warehouse projects split along a simple line. Where the work is on the face of the racking and the aisles are conventional, a self-propelled scissor lift does the job for the least money: the deck is large enough for two people, their tools and a replacement beam, and the extension deck reaches over the first row of pallets. Where the work is above the racking, over a conveyor or on the far side of a machine, an articulated boom or a mast lift with a jib becomes necessary because the platform has to arrive from above rather than from directly underneath.
We supplied a 10 m self-propelled scissor lift to a distribution centre in Kenya for exactly this kind of work: a 320 kg deck, a 2.27 x 1.12 m platform and a 0.9 m extension deck for reaching over the racking face, working at up to 12 m. On another project, a customer in Slovakia compared 8 m, 10 m and 12 m machines in the same enquiry because their racking bays were not all the same height, which is normal in a warehouse that has been extended over the years.
The details people forget
- Floor loading. A 12 m scissor lift weighs 3,000 kg and a 13.8 m machine 3,570 kg, spread over four wheels. Check what the mezzanine or the upper deck can take before assuming a scissor lift is the light option.
- The route in. A machine that fits the aisle but cannot pass the doorway or the goods lift at the end of it is useless. Our narrow 8 m model is 0.85 m wide for exactly this reason.
- Charging position. Battery machines need a charge point that does not block an aisle. Plan it before the machine arrives.
- Non-marking tyres. On finished warehouse floors, specify them; the alternative is a permanent set of black tracks.
- Sprinkler clearance. The platform and the operator both need to stay clear of sprinkler heads, which sometimes lowers the usable working height under a racking bay.
Frequently asked questions
Can I use a scissor lift in a racking aisle?
Yes, and it is the most common choice. Our main scissor platform is 2.27 x 1.12 m and the machine is 1.22 m wide, which fits a conventional racking aisle. For very narrow aisles or doorways below 1 m, the narrow 8 m model at 0.85 m wide with a 320 kg capacity is the version to specify.
When do I need a boom lift instead?
When the work point is not directly above the floor the machine can stand on: above the racking, beyond a conveyor, or behind a beam that cannot be moved. An articulated boom reaches over that obstacle with up to 8.54 m of up-and-over clearance, which a scissor platform cannot do at all.
How high do I need to go for typical warehouse racking?
Standard racking runs to about 6 to 8 m and high-bay installations to 10 to 12 m. Since working height is about 2 m more than platform height, a 6 m racking face needs roughly an 8 m working height machine, and a 10 m high-bay needs about 12 m of working height.
Next step
Tell us the height of your top beam, the aisle width, the narrowest doorway on the route and whether any work is above or behind the racking. We will recommend the machine and quote it, and if two machines would both do the job we will quote both so you can compare. See our electric scissor lifts, articulated boom lifts and aluminium mast lifts.