Choosing industrial shelving isn’t just about buying steel and shelves; it’s an important investment in your company’s operational efficiency, safety, and organization. Poor storage solutions lead to real costs: wasted floor space, lost or damaged inventory, inefficient workflows, and dangerous safety hazards that can halt productivity. A well-designed system, on the other hand, becomes a foundational asset that pays dividends for years to come.

Since 1901, Lyon has been America’s leading manufacturer of steel storage solutions, building systems designed to last a lifetime. Our goal with this guide is to give you a comprehensive, step-by-step process to help you choose the right industrial shelving system – one that supports your team, protects your inventory, and delivers long-term value for your business.

The first step: a 5-point checklist for assessing your storage needs

Before you even look at a single product, it pays to do your homework. Understanding your specific requirements is the key to selecting a system that works. This simple assessment will help you plan your storage solution with confidence.

1. What are you storing? Consider the physical characteristics of your inventory. Are you storing small parts, bulky boxes, or heavy components? Document the size, weight, shape, and quantity of the items. This information directly impacts the type of shelving and the shelf capacity you will need.
2. What is your environment? The setting determines the best material and finish. A dusty warehouse has different needs than a sterile cleanroom, a cold storage facility, or a professional office. The right finish, like a durable powder coat, will protect your investment from corrosion and wear.
3. How do you access it? Think about your workflow. Will your team be hand-picking items, using a rolling ladder for higher shelves, or operating heavy machinery like a forklift nearby? When designing your layout, consider the “golden zone” for picking ergonomics – the area between a worker’s shoulders and knees. Placing your fastest-moving or heaviest items within this zone minimizes bending, reaching, and stretching, which reduces physical strain and fatigue. This simple ergonomic principle can significantly boost picking speed and reduce the risk of workplace injuries. Your access method is important for determining appropriate shelving height and safe aisle width.
4. What is your space? Get out the measuring tape. You need to know your available square footage, but more importantly, your vertical cube space. Measure ceiling height and note any obstructions like columns, doorways, or sprinkler systems. Making the most of your vertical space is one of the fastest ways to improve storage density.
5. What are your future needs? Your business isn’t static, and your storage shouldn’t be either. Do you anticipate growth? A scalable, modular shelving system allows you to adapt and reconfigure your layout as your needs change, protecting your initial investment.

Shelving vs. racking: understanding the key difference

Many people use the terms “shelving” and “racking” interchangeably, but they refer to two distinct types of storage systems with different purposes. Choosing the correct one is important for safety and efficiency.

Shelving is designed for inventory that is loaded and picked by hand. It’s ideal for smaller, lighter, or individual items that don’t require machinery to move. Industrial shelving is the backbone of your picking and packing operations, tool cribs, and parts rooms.

Racking is a heavy-duty system built to store palletized loads. It is engineered to be loaded and unloaded using machinery like forklifts or pallet jacks. Racking is the solution for bulk inventory in a large warehouse or distribution center.

Feature	Industrial Shelving	Racking
Loading Method	Manual (by hand)	Manual or forklift
Typical Items	Boxes, bins, parts, tools	Bulky or Palletized goods
Weight Capacity	Lower (per shelf)	Higher (per bay)
Primary Use	Order picking, small parts	Bulk storage, distribution

Exploring the main types of industrial shelving systems

Once you’ve assessed your needs, you can explore the different types of industrial shelving to find the perfect fit. Lyon proudly manufactures a complete line of versatile, American-made shelving solutions.

Open steel shelving (8000 series and 2000 series)

• What it is: The workhorse of industrial storage. This versatile system features open sides and back, providing complete accessibility from all directions and promoting airflow.
• Best for: General purpose storage, bulk items, inventory rooms, and any application requiring high visibility and easy access to stored goods.
• Key features: Visibility from all four sides, easy to assemble, and highly configurable. Features Lyon’s compression clips, which allow for fast, tool-free adjustment of shelf heights. As weight is added, the clip design gets tighter and stronger, locking the shelf firmly in place.
• Lyon’s solution: Our 8000 Series is proudly made in the USA with heavy-gauge steel, offering exceptional strength and a lifetime warranty to ensure it’s built to last.
• Learn more: Explore our Open Steel Shelving systems.

Closed steel shelving (8000 series and 2000 Series)

• What it is: This system starts with the same posts of open shelving and adds steel side and back panels. These panels enclose the unit, providing greater stability and product protection.
• Best for: Storing small or loose parts, preventing items from falling off the back or sides, creating clearly defined storage bays, and for use in office or retail environments for a finished look.
• Key features: Better product security and containment, increased structural rigidity, and a clean, professional appearance. Incorporates Lyon’s tool-free compression clips for fast shelf adjustments – a design proven for over 50 years to get stronger under load.
• Lyon’s solution: Lyon’s closed shelving provides a strong and rigid assembly, perfect for organizing tool cribs, service counters, and parts departments where containment is key.
• Learn more: Discover our Closed Steel Shelving options.

Bin shelving (8000 series)

• What it is: A high-density storage solution that integrates dividers or plastic bins directly into the shelving unit. It’s engineered specifically for organizing small parts.
• Best for: Kitting operations, hardware storage, electronics, automotive parts, and any inventory with a high number of small SKUs that need to be separated and easy to pick.
• Key features: Maximizes storage density, improves picking accuracy by assigning a location to every part, and keeps small items perfectly contained. Our tool-free compression clips make it simple to reconfigure shelf levels as your inventory changes.
• Lyon’s solution: Our integrated bin shelving systems ensure everything is in its place, helping you reduce search time, minimize picking errors, and boost overall productivity.
• Learn more: See how Bin Shelving can organize your inventory.

Bulk storage racks (bulk shelving)

• What it is: A hybrid system that bridges the gap between standard shelving and heavy-duty pallet racking. It’s designed for heavy, wide, or bulky items that are still loaded by hand.
• Best for: Manual loading of wide or heavy cartons, archival record boxes, and industrial supplies that are too large for standard shelving but don’t require a pallet.
• Key features: Wide, unobstructed spans for bulky items and a high weight capacity per shelf level. While particle board is a common decking option, wire decking is a superior alternative. It improves safety by allowing light to filter to lower levels and increasing sprinkler system effectiveness, and it prevents dust accumulation, making it ideal for facilities where cleanliness and fire safety are top priorities.
• Lyon’s solution: Lyon’s bulk storage racks are the cost-effective solution for when standard shelving isn’t strong enough, providing strong support you can rely on.
• Learn more: Find the right Bulk Storage Racks for your application.

Mobile aisle shelving

• What it is: A high-density system where shelving units are mounted on wheeled carriages that move along a track system. By compacting together, these systems eliminate all but one “floating” aisle.
• Best for: High-density storage in limited footprints, secure record storage, and parts departments.
• Key features: Can double your storage capacity in the same square footage, offers options for manual-assist or powered operation, and can be secured for sensitive materials.
• Lyon’s solution: Our mobile aisle systems are engineered for smooth, reliable operation, transforming your storage density and freeing up valuable floor space for other activities.
• Learn more: Explore our Mobile Shelving solutions.

Key buying considerations: a look at the details that matter

The difference between good shelving and great shelving is in the details. Focusing on these key factors will ensure you select a system that is safe, durable, and reliable for decades.

Load capacity: the #1 factor for safety and longevity

Understanding and respecting load capacity is non-negotiable for workplace safety. You need to know the difference between shelf capacity (the maximum weight a single shelf can hold) and upright capacity (the maximum weight the entire unit can hold). Overloading is a primary cause of shelving failure and can lead to catastrophic accidents. Pay close attention to the steel gauge of components and the design of the shelf beams and reinforcements, as these directly impact capacity.

Expert Tip: Always calculate your required capacity per shelf and then add a 25% safety margin. It’s better to have more capacity than you need than not enough.

Materials, construction, and finish: what “built to last” really means

The durability of your shelving system starts with the raw materials.

• Quality steel: Lyon uses only high-quality steel. We control the entire process from coil to finished product, ensuring unmatched durability and consistency. The gauge of the steel is important – a heavier gauge (lower number) means a stronger, more durable product.
• Construction: The way a unit is assembled impacts its stability. Lyon’s signature T-post upright and beaded post designs offer superior strength and rigidity compared to traditional angle posts. Its unique shape provides a common post between adjacent shelving sections, which saves space and simplifies installation. Angle posts are also available for more cost effective solutions.
• Finish: A superior finish protects the steel and extends the life of your investment. Our durable powder coat paint finish is applied electrostatically and then cured, creating a much tougher shell than standard liquid paint. Our powder coat finish resists scratches and corrosion, ensuring your investment looks and performs its best for decades.

As part of our commitment to sustainability, Lyon also uses environmentally friendly manufacturing processes that comply with LEED standards.

Safety and compliance: protecting your people and your business

Safety should be at the forefront of any storage project. Look for products that are designed and tested to meet recognized industry standards, such as those from ANSI/BIFMA.

• Anchoring: Properly anchor all industrial shelving units to the floor and/or wall to prevent tipping. This is especially important in seismic zones or for tall units.
• Seismic Considerations: For facilities located in seismically active zones, it is critical to use shelving engineered for seismic conditions. Lyon offers seismic-rated shelving that includes heavier-duty posts, additional bracing, and/or specific anchoring requirements to ensure the unit remains stable during a seismic event. This isn’t just a recommendation; it’s often a legal requirement for compliance with local building codes.
• Installation: For large or complex systems, we strongly recommend professional installation. Our nationwide network of 20+ solutions experts ensures your system is assembled correctly, safely, and in compliance with all regulations.
• Regular inspections: You can protect your team by conducting regular visual inspections. Check for signs of damage (dents, bent beams), ensure components are secure, and verify that units are not overloaded.

The smart buyer’s matrix: budgeting and calculating true ROI

A smart investment looks beyond the initial price tag. By understanding the total cost of ownership and the potential return on investment, you can make a smarter purchasing decision.

Beyond the sticker price: understanding total cost of ownership (TCO)

The cheapest option is rarely the most cost-effective one. TCO includes:

• Initial cost: The price of the shelving itself.
• Installation cost: The labor and time required for assembly.
• Maintenance cost: High-quality shelving requires minimal maintenance.
• Replacement cost: When damage occurs, there’s no need to replace entire runs of shelving. Replace individual components as needed to keep your shelving in prime condition. 

A one-time investment in Lyon’s steel shelving is more cost-effective over its lifetime than replacing cheaper, imported alternatives two or three times.

Calculating the return: how a better shelving system pays for itself

The right storage system isn’t an expense; it’s an investment that generates returns by:

• Increasing storage density: Freeing up valuable floor space for revenue-generating activities like production or shipping.
• Improving labor efficiency: Organizing inventory for faster picking and put-away times directly reduces labor costs.
• Reducing inventory loss: Proper organization and containment protect products from damage, misplacement, and loss.
• Improving safety: A safe workplace is a productive one. You can avoid the immense direct and indirect costs associated with workplace accidents.

Industry-specific solutions: shelving engineered for your application

Lyon has proudly served America’s industries for over 125 years. We have the expertise to recommend the ideal solution for your specific needs.

Warehouses and distribution centers

• Focus: Durability to withstand daily use, high capacity for heavy loads, and efficient design for fast order picking.
• Recommended products: Bulk Storage Racks for heavy cartons, and 8000 Series Open and Bin Shelving for pick-and-pack areas.

Military and GSA contracts

• Focus: Uncompromising security, heavy-duty construction, and compliance with government standards.
• Recommended products: Shelving, Modular Drawer Cabinets for secure storage, and welded storage cabinets for weapons.

Schools and athletic facilities

• Focus: Durability for heavy use, safety for students and athletes, and organization for gear, equipment, and supplies.
• Recommended products: Ventilated Lockers for athletic gear and heavy-duty closed shelving for equipment rooms.

Healthcare and labs

• Focus: Cleanliness, precise organization, and secure storage for sensitive medical supplies and records.
• Recommended products: Closed shelving with smooth, easy-to-clean surfaces and high-density mobile aisle systems for patient records.

Frequently asked questions (FAQ)

How do I assemble Lyon industrial shelving?

Our shelving is designed for straightforward assembly. Starter units consist of two upright assemblies (sides), while add-on units use one upright assembly (side) and attach to the starter, simplifying installation. We provide detailed instruction manuals you can find on our website. For large projects, we recommend ordering through one of our distributors that can also offer professional installation services.

What is the standard lead time for shelving orders?

Thanks to our three centrally located domestic plants, Lyon maintains a large in-stock inventory of our most popular products. Thousands of items are ready to ship quickly, so you can complete your project on schedule.

Can I add to my Lyon shelving units later?

Yes. Modularity is a key feature of our shelving systems. You can easily add more units (add-ons) to an existing row of shelving as your storage needs grow, making it a scalable and cost-effective solution.

What is the advantage of a powder coat finish?

A powder coat finish is significantly more durable than standard paint. It creates a thick, resilient surface that is highly resistant to scratches, chipping, and corrosion. This means your shelving will look better and last longer, even in tough industrial environments.

Do you offer design and layout services?

Absolutely. We have a team of over 20 solutions experts nationwide who are ready to help. We will be happy to assist you with a comprehensive storage plan, from initial assessment to final layout design, ensuring you get the most efficient and effective system for your space.

Your partner in storage since 1901

Choosing the right industrial shelving is an important decision that impacts the safety, efficiency, and productivity of your entire operation. It’s an investment in putting everything in its place so you can keep on working.

With Lyon, you’re choosing more than just a product. You’re choosing American-made quality backed by a lifetime warranty. You’re choosing a partner with over 125 years of expertise and a team of dedicated professionals ready to support you. Don’t leave your storage solution to chance. Request a Quote and one of our experts will reach out to you for a free consultation. We’ll help you design a system that’s built to last and delivers a real return on your investment.