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Case Study: Warehouse Racking System

Alliance Carpets

Large-scale racking system designed to optimize forklift movement and storage density across a 150-metre warehouse

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PROJECT OVERVIEW

Palletower worked with Alliance Carpets to plan and install a large-scale warehouse racking system capable of storing 25,000 carpet rolls and 2,100 pallets.

Project Type:

Warehouse Racking System

Industry:

Retail & Supply Chain

Requirement:

High-Capacity Storage Integration

The brief 

Palletower first began discussions with Alliance Carpets in 2018, when the company was exploring racking options for an existing property. The brief later changed when Alliance decided to build a new facility. 

The new warehouse required a substantial storage system for carpet rolls and palletised stock. The project involved 12 months of planning followed by a three-month installation programme. 

The challenge 

Accuracy was essential because of the scale of the building. Palletower worked closely with the building contractor to understand the column layout, then carried out detailed measurements once construction was complete to avoid cumulative errors across the space. 

The 150-metre rack runs also created operational challenges. Forklift travel needed to be reduced without compromising storage capacity. The design also had to accommodate carpet cutting and sortation machines, floor expansion joints and safety requirements for back-to-back racks. 

Supply chain disruption created further pressure, with timber and steel prices affected by the war in Ukraine. 

 

PROJECT DETAILS

Palletower’s solution 

Palletower introduced 3.9 metre bridge bays at agreed intervals to improve forklift access and reduce travel distances. These were carefully positioned with Alliance to support day-to-day warehouse efficiency. 

The racking layout was adapted around carpet cutting and sortation machines. In one area, a heavy-duty structural steel frame was installed above the machines to create additional storage. Palletower also worked with the building contractor to align pre-drilled floor holes with pallet racking footplates so that the rack could be securely bolted in place. 

Detailed drawings were supplied to help avoid floor expansion joints and preserve efficient bay lengths. Net curtains were installed between back-to-back racks to prevent products being pushed through, and more than a kilometre of bump rails were fitted to guide forklifts and protect the racking. 

To manage supply chain disruption, Palletower sourced timber from Scandinavia and provided Alliance with a firm cost once stability returned. 

The result 

The finished system delivered a safe, durable and efficient storage environment for Alliance Carpets. The project demonstrates Palletower’s ability to manage large-scale industrial racking projects while adapting to changing site, supply chain and operational requirements. 

Key outcomes 

  • Storage designed for 25,000 carpet rolls and 2,100 pallets 
  • Bridge bays to improve forklift movement 
  • Racking adapted around operational machinery 
  • Safety features including net curtains and bump rails 
  • Procurement support during supply chain disruption 

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Cargopak Ltd are now part of Palletower, Europe's largest providers of storage and logistic equipment.