When people search for "Lye Designs", they're often looking for information about our approach to custom racking design at Wong Lye Racking. We're not a catalogue supplier — every system we fabricate starts with a site survey, a load calculation against your actual pallet weights, and a layout drawn around your forklift fleet and floor slab capacity. This is how we've approached design work since 2014, across more than 1,500 installations in Singapore warehouses, 3PL hubs, and factory storage zones.

What "Lye Designs" Means in Practice

We don't sell racking by browsing a product brochure. When a client comes to us, the first thing we do is visit the site. We measure the floor slab, check for drains or obstructions, confirm ceiling height and sprinkler positions, ask about the forklift model and lift height, and get the actual pallet dimensions and load weights — not the theoretical maximum, but the real SKU mix that will sit on those beams.

From there, we design the rack system to fit the space and the operation. That means:

• Beam spacing sized to the pallet height and overhang, not a standard 1,200 mm grid
• Upright section rated for the actual load per bay, calculated with a safety factor and checked against slab capacity
• Aisle width based on the forklift's turning radius and mast reach, so operators can work without constant three-point turns
• Anchoring and bracing coordinated with the floor slab thickness and rebar — we've seen plenty of racks sold with the wrong anchor spec because no one checked the slab report

We then fabricate the uprights, beams, and accessories in-house in Singapore using cold-roll forming and beam end-plate welding. Heavy-section profiles for our Super Heavy-Duty tier are imported, but everything is PSB-tested and comes with mill certificates on request. We don't outsource fabrication and rebrand it — we make it, we test it, we install it, and we're the ones you call if anything needs adjustment two years later.

Why We Started Designing Our Own Racks

We didn't set out to become a racking manufacturer. Wong Lye started in 2011 as a logistics business. In 2014, we needed racks for our own warehouse. We contacted a few suppliers, but every quote was based on standard sizing with no site survey, no load calculation, and no discussion of our actual forklift or pallet mix. One contractor insisted on 2,700 mm beam levels even though our pallets were 1,400 mm tall — pure wasted height. Another quoted uprights that would have overloaded our ground-floor slab.

So we designed and built our own. We did the load calculations ourselves, fabricated the steel, and installed it with our own crew. The racks worked. Clients who visited the warehouse asked who built them. We said we did. They asked if we could do theirs. That became the racking division.

Two decades and 1,500+ projects later, the approach hasn't changed: we design to the real conditions, not the catalogue. That's what "Lye Designs" means — bespoke engineering for your actual operation, not a one-size-fits-most spec sheet.

The Design Process: Survey, Calculate, Draw, Fabricate

Here's how we work through a typical project, whether it's a 200-pallet Selective system or a 4,000-pallet VNA layout:

1. Site Survey and Load Interview

We visit the site and measure everything that affects the rack layout: floor slab thickness and condition, column positions, door clearances, ceiling height, sprinkler head locations, electrical conduit runs, and any planned mezzanine or office zones. We also ask about the forklift fleet — model, mast type, lift height, and turning radius. Then we get the pallet and load data: dimensions, weight per pallet (actual, not theoretical), SKU turnover, and whether loads are uniform or variable.

2. Load Calculation and Upright Sizing

We calculate the load per bay and per beam level, apply a safety factor, and size the upright and beam sections accordingly. If the total rack load exceeds the slab's rated capacity (common in older industrial buildings), we flag it and discuss options: load distribution across more bays, slab reinforcement, or a lighter rack configuration. We've stopped more than one project at this stage because the floor simply couldn't take the weight — better to know before fabrication than after a slab crack appears.

3. Layout Drawing and Forklift Simulation

We draw the rack layout in CAD, showing aisle widths, bay spacing, and beam levels. We overlay the forklift's turning radius and mast reach to confirm that operators can access every pallet position without tight manoeuvring. If the layout doesn't work, we adjust the aisle width or rack orientation before a single piece of steel is cut.

4. Fabrication and PSB Testing

Once the design is approved, we fabricate the components in-house: cold-roll forming for uprights, beam end-plate welding, powder coating, and accessory assembly. Every batch is PSB-tested for load capacity, and we keep mill certificates on file. If a client needs documentation for an insurance audit or a BCA mezzanine submission, we provide it.

5. Installation and Handover

Our crew installs the racks, checks plumb and level, and anchors to the slab with the correct bolt spec. We don't subcontract installation — the same team that fabricates the steel is on-site to install it. After handover, we provide a layout drawing, a load placard for each bay, and a contact number for any future adjustments or expansions.

When Clients Come to Us Mid-Project (or Mid-Problem)

A fair portion of our work involves fixing or replacing racks that were sold without proper design. We've seen:

• Selective racks with beam levels spaced so tightly that pallets couldn't be lifted without hitting the level above
• Drive-In systems with rail heights that didn't match the forklift's fork carriage, resulting in repeated impacts and bent rails
• VNA racks installed in aisles too narrow for the wire-guided truck to turn at the end of the run
• Cantilever arms sized for timber loads but loaded with steel coils, causing visible deflection within six months
• Mezzanine floors built without checking the ground-floor slab capacity, leading to differential settlement and cracked tiles

In every case, the original supplier had sold a standard system without surveying the site or asking about the actual loads and equipment. The client paid twice — once for the catalogue rack, once for us to redesign and replace it. That's the cost of skipping the design step.

What We Don't Do (and Who to Contact Instead)

We design and install industrial racking, mezzanine floors for warehouses, and outdoor shelters for logistics yards. We do not handle interior renovation fit-outs, HDB flat works, or lightweight residential shelving. If your project involves HDB-licensed renovation, contact our sister company Larry Contractors at contractors.com.sg. If you need structural building works for a landed property (foundations, extensions, roof works), that's handled by Wong Lye's BCA General Builder Class 2 division at wonglye.com.

For warehouse racking, mezzanine storage platforms, and industrial shelters in Singapore — especially if you need a design process that starts with your actual site conditions, not a product catalogue — that's what we do.

Frequently Asked Questions

What does "Lye Designs" refer to?

"Lye Designs" refers to our custom racking design and fabrication service at Wong Lye Racking. We survey your site, calculate loads based on your actual pallets and forklift, design the rack layout to fit your space and slab capacity, then fabricate and install the system in Singapore. It's a bespoke engineering process, not a catalogue order.

Do you charge separately for the design work?

We include the site survey and initial layout drawing in our quotation at no separate charge. If the project requires detailed CAD drawings for a BCA submission (common for mezzanines or PE-stamped racks), we coordinate that as part of the scope and itemise it in the quote. We don't charge for a basic load calculation or aisle layout — that's part of responsible racking design.

Can you redesign or replace racks that another contractor installed?

Yes, we've done this many times. We survey the existing system, assess what can be reused (if anything), calculate the correct sizing for your actual loads and forklift, then fabricate and install the replacement racks. In some cases we can reinforce or modify the existing frames; in others, a full replacement is safer and more cost-effective. We'll walk you through the options after the site visit.

How long does a custom racking project take from survey to installation?

For a straightforward Selective or Drive-In system, expect two to four weeks from survey to installation: one week for design and quotation approval, one to two weeks for fabrication, and a few days for installation depending on the system size. Larger projects (VNA, multi-tier mezzanines, or systems requiring BCA/SCDF submissions) can take six to eight weeks. We give a realistic timeline during the quotation stage, and we update clients if fabrication or site access changes the schedule.

Do you only work with large warehouses, or can you design racks for smaller factory storage areas?

We work with both. Some of our projects are 4,000-pallet 3PL hubs; others are 200-pallet factory storage zones or workshop cantilever racks for long materials. The design process is the same regardless of scale: survey, load calculation, layout tailored to your forklift and space, then fabrication and installation. If you need industrial-grade racking in Singapore and you want it sized correctly from the start, the project size doesn't matter — the method does.

Get a Custom Racking Design for Your Warehouse

If you're planning a new racking installation, expanding an existing system, or replacing racks that were never quite right, we'd like to hear about it. We'll visit your site, measure the space, review your loads and forklift fleet, and design a system that actually fits your operation. No catalogue guesswork, no standard sizing that "should work" — just a proper survey, a proper calculation, and steel fabricated to match.

Reach us on WhatsApp at +65 9107 2601 or visit our site at rackings.com.sg. We'll arrange a site visit and walk you through what a properly designed racking system looks like for your warehouse.