In today’s competitive business landscape, warehouses play an increasingly important role in today’s economy. Centralising operations, rationalising inventory, and leveraging cutting-edge technology is enabling businesses to achieve these performance and cost benefits.
Warehouses have evolved from storage spaces into dynamic, multi-functional units vital to modern supply chains. They are used for picking and dispatching orders for online sales, holding stock for retail outlets, and overseeing reverse logistics. The surge of e-commerce and the need for efficient delivery systems has seen demand for these facilities grow. Centralising operations has seen warehouses expand in size and complexity, both in terms of footprint and height. According to a report by Savills, the number of warehouse units exceeding 1 million square feet has increased by 345% since 2015.
Designing Racking Systems to New Heights
As warehouses scale, the racking industry faces new challenges in accommodating these larger, complex structures. High-reach automated cranes, paired with sophisticated warehouse management systems (WMS), are enabling storage systems to increase in height and capacity.
While extending racking systems to greater heights offers significant advantages for the logistics industry, it requires a cautious and informed approach. Manufacturing pallet racking that exceed heights of 40 metres demands a deep understanding of engineering principles and meticulous planning.
When designing high-rise racking, there are several critical factors for consideration, including the type and weight of the stock being stored and the specific demands of automated handling systems. High-rise structures impose lateral loads that are not typically a concern in low-rise racking systems, requiring designs that withstand these additional stresses.
Case Study: The Challenges of Building Higher Racking
The complexities of designing and constructing high-rise racking systems were demonstrated in a recent project. Leading storage solutions provider Link51 was tasked with designing, manufacturing, and installing a bespoke racking system for a major logistics and supply chain specialist. The project involved the creation of an automated dark warehouse spanning an area equivalent to 11 football pitches, with 6,424 full bays of high-bay, crane-fed pallet racking. The racking system, which reaches an impressive height of 33 metres, represents one of the tallest storage solutions in the UK.
The sheer size of the system presented numerous challenges. To accommodate the double-deep cranes used in the warehouse, Link51 designed a bespoke pallet support system that elevates the pallets off the beams and provide suitable clearance to ensure smooth operation. As a fully automated warehouse, each aisle also required dedicated crane maintenance areas. These platforms, which allow engineers access for maintenance, are located at the top end of each bay and slide out to span the width of the aisle. These were installed after the racking was erected and Link51 collaborated with a specialist company to develop this innovative solution.
The construction of the racking system took nearly 10 months and features double-deep racking spans across 13 levels, with 22 aisles and 73 full bays capable of holding 165,320 net pallet positions.
The Future of Automated Racking Systems and Link51’s Commitment to Innovation
As the demand for more efficient and scalable warehouse solutions continues to grow, the role of automated racking systems will become increasingly critical. Product development and innovation are essential to Link51 as they continue to anticipate the future needs of their customers and meet increasingly stringent technical standards and challenging applications. The coming months will see Link51 introduce a new pallet racking range that leverages their latest manufacturing assets, ensuring they are well-positioned to meet evolving market demands. With the rise of automation and the need to maximise warehouse space by going higher, Link51 is at the forefront of this industry evolution
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