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Case Study: Cantilever Racking and Guide Rail

Cantilever Racking and Guide Rail Installation

Palletower supported a client with a phased Cantilever Racking and Guide Rail installation, designed to maximise storage locations within an existing warehouse. Delivered across two phases and built around a 1600mm forklift aisle requirement, the project achieved 3,240 storage locations, enabling the client to consolidate stock and close down another site.

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PROJECT OVERVIEW

Cantilever Racking and Guide Rail installation delivering 3,240 storage locations

Project Type:

Cantilever Racking and Guide Rail

Industry:

Industrial Steel & Metals

Requirement:

Create additional storage locations

The brief

Palletower was approached by the client to support the design of a Cantilever Racking layout within their existing warehouse, with the aim of achieving as many storage locations as possible.

The project would allow the client to consolidate stock from another site, ultimately enabling that site to close and reducing overhead and leasing costs. From the early stages, discussions involved Palletower, the client, a supplier, and competing suppliers who were also pitching for the work.

The challenge

The project was split into two phases, C&D Bay and J Bay, each carried out within a warehouse divided into several bays. Every bay had a maximum width to work within, which made achieving the number of racks and locations the client needed a careful balancing act.

A new concrete slab also had to be laid ahead of both phases, and during phase one it became clear the slab hadn’t been laid within tolerance, causing complications when fitting the guide rail. The design also had to accommodate the client’s incoming forklift truck, which required a 1600mm aisle width throughout.

PROJECT DETAILS

Palletower’s solution

Palletower designed and installed a Cantilever Racking and Guide Rail system, working to 3m column centres to allow the client to store steel lengths of up to 6m. To make sure the solution met the client’s exact requirements, Palletower held detailed discussions with the client, carried out a full site survey, and produced CAD drawings to guide the installation. The project was delivered in partnership with the supplier alongside Palletower.

The result

The finished installation delivered 3,240 storage locations, giving the client the additional capacity needed to consolidate stock and close their other site. With more storage now available, the client is better placed to support future growth and improve lead times for their own customers.

Key outcomes

  • Increased storage locations to 3,240
  • Reduced costs by bringing product storage under one roof
  • Client now utilising the height of the building rather than relying on ground floor storage
  • Improved stock retrieval, with a single location for each product type
  • Improved warehouse efficiency
  • Guide rail fitted to the front of each run of Cantilever Racking to create a safe working aisle for forklift trucks
  • Adjustable arms fitted to accommodate different product types and heights across levels

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