Dimensionning a Warehouse

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1. Overview

Here is a very rough example of a warehouse layout.

In this section we are going to size the various zones:

2. Zones of stock

For this, we are going to use an elementary zone of 6 pallets as described in the following drawing:

2.1. Surface Calculation

Thanks to the elementary zone, we have the following hypotheses and the following ratios

2.1.1. On the ground

Warehouse Ratio palet per m2
This ratio includes service alleys but not circulation alleys

Forklift	Bidi	Tridi	Small Stacker	Retractil	Frontal 3 wheels	Frontal 4 wheels

Elementary Zone dimensions
X Dimensions	2,92	2,92	2,92	2,92	2,92	2,92
Palets (2x1,2)	2,4	2,4	2,4	2,4	2,4	2,4
Shelves support	0,12	0,12	0,12	0,12	0,12	0,12
Allowances	0,4	0,4	0,4	0,4	0,4	0,4
Y Dimensions	4,22	4,42	4,62	5,42	6,12	7,12
Palets (2x1,2)	2,4	2,4	2,4	2,4	2,4	2,4
Service Alleys	1,6	1,8	2	2,8	3,5	4,5
Allowances	0,22	0,22	0,22	0,22	0,22	0,22

m2/p on floor	2,05	2,15	2,25	2,64	2,98	3,47

2.1.2. Using racks storage

Warehouse Ratio palet per m2
This ratio includes service alleys but not circulation alleys

Forklift	Bidi	Tridi	Small Stacker	Retractil	Frontal 3 wheels	Frontal 4 wheels

Elementary Zone dimensions
X Dimensions	2,92	2,92	2,92	2,92	2,92	2,92
Palets (2x1,2)	2,4	2,4	2,4	2,4	2,4	2,4
Shelves support	0,12	0,12	0,12	0,12	0,12	0,12
Allowances	0,4	0,4	0,4	0,4	0,4	0,4
Y Dimensions	4,22	4,42	4,62	5,42	6,12	7,12
Palets (2x1,2)	2,4	2,4	2,4	2,4	2,4	2,4
Service Alleys	1,6	1,8	2	2,8	3,5	4,5
Allowances	0,22	0,22	0,22	0,22	0,22	0,22

m2/p on floor	2,05	2,15	2,25	2,64	2,98	3,47

Forklift	Bidi	Tridi	Small Stacker	Retractil	Frontal 3 wheels	Frontal 4 wheels
Palet/m2
1 nivel	0,49 p/m2	0,46 p/m2	0,44 p/m2	0,38 p/m2	0,34 p/m2	0,29 p/m2
2 nivels	0,97 p/m2	0,93 p/m2	0,89 p/m2	0,76 p/m2	0,67 p/m2	0,58 p/m2
3 nivels	1,46 p/m2	1,39 p/m2	1,33 p/m2	1,14 p/m2	1,01 p/m2	0,87 p/m2
4 nivels	1,95 p/m2	1,86 p/m2	1,78 p/m2	1,52 p/m2	1,34 p/m2	1,15 p/m2
5 nivels	2,43 p/m2	2,32 p/m2	2,22 p/m2	1,90 p/m2	1,68 p/m2	1,44 p/m2
6 nivels	2,92 p/m2	2,79 p/m2	2,67 p/m2	2,27 p/m2	2,01 p/m2	1,73 p/m2
7 nivels	3,41 p/m2	3,25 p/m2	3,11 p/m2	2,65 p/m2	2,35 p/m2	2,02 p/m2
8 nivels	3,90 p/m2	3,72 p/m2	3,56 p/m2	3,03 p/m2	2,69 p/m2	2,31 p/m2
9 nivels	4,38 p/m2	4,18 p/m2	4,00 p/m2	3,41 p/m2	3,02 p/m2	2,60 p/m2
10 nivels	4,87 p/m2	4,65 p/m2	4,45 p/m2	3,79 p/m2	3,36 p/m2	2,89 p/m2
11 nivels	5,36 p/m2	5,11 p/m2	4,89 p/m2	4,17 p/m2	3,69 p/m2	3,17 p/m2
12 nivels	5,84 p/m2	5,58 p/m2	5,34 p/m2	4,55 p/m2	4,03 p/m2	3,46 p/m2
13 nivels	6,33 p/m2	6,04 p/m2	5,78 p/m2	4,93 p/m2	4,36 p/m2	3,75 p/m2
14 nivels	6,82 p/m2	6,51 p/m2	6,23 p/m2	5,31 p/m2	4,70 p/m2	4,04 p/m2
m2/Palet
1 nivel	2,05 m2/p	2,15 m2/p	2,25 m2/p	2,64 m2/p	2,98 m2/p	3,47 m2/p
2 nivels	1,03 m2/p	1,08 m2/p	1,12 m2/p	1,32 m2/p	1,49 m2/p	1,73 m2/p
3 nivels	0,68 m2/p	0,72 m2/p	0,75 m2/p	0,88 m2/p	0,99 m2/p	1,16 m2/p
4 nivels	0,51 m2/p	0,54 m2/p	0,56 m2/p	0,66 m2/p	0,74 m2/p	0,87 m2/p
5 nivels	0,41 m2/p	0,43 m2/p	0,45 m2/p	0,53 m2/p	0,60 m2/p	0,69 m2/p
6 nivels	0,34 m2/p	0,36 m2/p	0,37 m2/p	0,44 m2/p	0,50 m2/p	0,58 m2/p
7 nivels	0,29 m2/p	0,31 m2/p	0,32 m2/p	0,38 m2/p	0,43 m2/p	0,50 m2/p
8 nivels	0,26 m2/p	0,27 m2/p	0,28 m2/p	0,33 m2/p	0,37 m2/p	0,43 m2/p
9 nivels	0,23 m2/p	0,24 m2/p	0,25 m2/p	0,29 m2/p	0,33 m2/p	0,39 m2/p
10 nivels	0,21 m2/p	0,22 m2/p	0,22 m2/p	0,26 m2/p	0,30 m2/p	0,35 m2/p
11 nivels	0,19 m2/p	0,20 m2/p	0,20 m2/p	0,24 m2/p	0,27 m2/p	0,32 m2/p
12 nivels	0,17 m2/p	0,18 m2/p	0,19 m2/p	0,22 m2/p	0,25 m2/p	0,29 m2/p
13 nivels	0,16 m2/p	0,17 m2/p	0,17 m2/p	0,20 m2/p	0,23 m2/p	0,27 m2/p
14 nivels	0,15 m2/p	0,15 m2/p	0,16 m2/p	0,19 m2/p	0,21 m2/p	0,25 m2/p

2.2. Stock area max Heights

2.2.1. Forklift trucks

Max Height of higher storage nivel per forklift type

Forklift	Bidi	Tridi	Retractil	Frontal artic.	Preparator	Frontal
Max heigh	14 m	14 m	11 m	10 m	9 m	7 m

2.2.2. Operators

Max Height of higher storage nivel for workers

Between	0,55 y 1,8 m
Higher	1,6 m
High frequency good	<0,6 m

If a worker prepares in a shelves storage area, the first level of shelves should be at 2m min.

3. Traffic Zones

3.1. Interior

Width of alleys in a warehouse

Interior
Forklift	Bidi	Tridi	Small Stacker	Retract	Frontal 3 wheels	Frontal 4 wheels	Frontal artic.
Service Alleys	1,6 m	1,7m to 1,9m	2m to 3m	2,8m to 3m	3,5 to 4m	4m to 4,5m	1,8m to 2,1m
Circulation Alleys**	4,5 m	4,5 m	-	3,5 m	3,5 m	4,5 m	3m
Pedestrian pathways	0,75m to 1,15m
*Dimensions min.
**Wider circulation alleys (5m to 6,5m) allow a better productivity.

3.2. Exterior

Vehicle Types	Cars		Trucks
Vehicle Types	min	max	min	max
One Way	3 m	-	4 m	-
Two Ways	5 m	-	6,5 m	-
In front of Doors clearance	15 m	25 m	30 m	35 m

4. Zones of reception and expedition

Accesses of reception and expeditions can be of different sizes but must be sized according to the Lorries dimensions using them:

	Lenght	Width max	Height
Standard Truck	12,00 m	2,44 m	2,70 m
Trailer	16,50 m	2,50 m	2,70 m
Trailer++	16,50 m	2,50 m	3,10 m

The distance between these accesses is important:

Distance between 2 docks axis = 4.50m (4m min)
Distance between two docks doors (edge-to-edge) = 2.05m (1.25m palet*allowance + 0.8m man)

Loading dock: Height = 1.15m + a leveler +- 10 % on 3m

Leveler:

Length: 2 to 4 m
Width: 2 to 2.20m

5. Offices & Services areas

The following ratios are a good indication for a fast dimensioning. In detailed project phase, it would be advisable to refine them:

	Min	Max	Coments
Staff Office	9 m2/pers	12 m2/pers
Management Office	15 m2/pers	20 m2/pers
Meeting room	2 m2/pers	2,5 m2/pers
Rest area	0,24 m2/pers	0,24 m2/pers	12% of total staff at same time
Infirmary	25 m2	25 m2
Medical office	16 m2	16 m2
Kitchen	= 0,44 * qty pers + 83
Eating Room	1,30 m2/pers
Cloakroom	1 m2/pers	1 m2/pers
Toilets	0,2 m2/man y 0,3 m2/woman
Parking	20 m2/vh	25 m2/vh	inc. Circulacion alleys