Section 1: Measuring Warehouse Spatial Constraints (Determining Maximum Footprint)
Clear Floor Dimensions: Use a laser measure or tape measure to determine the net usable floor space. Focus on the inner clearance between structural columns rather than wall-to-wall distances, as column spacing directly dictates how many continuous bay runs can be installed.
Vertical Clearance (Clear Height): Measure from the finished floor to the lowest overhead obstruction, which is typically the underside of roof beams or fire sprinkler heads. The maximum total height of the Storage Shelves must maintain a 300 mm to 500 mm (12" to 20") safety buffer below this point to allow adequate clearance for forklift operations.
Access Points: Measure the clear width and height of all warehouse entrance doors and docks to ensure that long uprights and beams can be safely transported into the facility during delivery.
Section 2: Measuring Loads and Pallets (Determining System Configuration)
Actual Pallet Dimensions: Do not rely solely on nominal "standard" sizes. Physically measure the actual length and width of the pallets being used, as wooden pallets often vary by several centimeters due to manufacturing tolerances or wear.
Total Load Height: Measure the total height of the unit load from the base of the pallet to the highest point of the stacked goods.
Section 3: Calculating Specific Dimensions for Storage Shelves
Frame Depth (Front-to-Back): The depth of the upright frame should be slightly less than the depth of the pallet. For example, if your pallet depth along the fork-entry direction is $1200\text{ mm}$, a frame depth of $1100\text{ mm}$ or $1050\text{ mm}$ is typically selected. This allows a 50 mm to 75 mm pallet overhang at both the front and back, ensuring stable positioning on the load beams.
Bay Length / Beam Clear Span (Left-to-Right): To calculate the required beam length per bay, take the combined width of the pallets placed side-by-side and add a clearance margin of 100 mm to 150 mm (4" to 6"). This leaves a 50 mm to 75 mm safety gap between the pallets and the upright columns, as well as between the pallets themselves, preventing collisions during forklift placement. The total run length is the sum of these beam spans plus the actual width of the upright column profiles.
Compartment Height / Beam Spacing (Vertical): The clear vertical height for each level must equal the Total Load Height plus a 100 mm to 150 mm (4" to 6") lift clearance, allowing operators enough room to raise and maneuver the pallet off the beams safely.
Section 4: Operating Aisle Width Requirements
Aisle dimensions are governed strictly by the Minimum Aisle Width (AST) specifications of the specific forklift fleet utilized:
Standard Counterbalance Forklifts: Require an operating aisle width of 3.5 to 4.0 meters (11.5' to 13').
Reach Trucks: Can operate efficiently in narrowed aisles of 2.7 to 3.0 meters (9' to 10').
Very Narrow Aisle (VNA) Turret Trucks: Optimized for high-density storage, reducing required aisle widths down to 1.6 to 2.0 meters (5.2' to 6.5').
