How to Calculate Forklift Aisle Widths For Your Warehouse

Warehouses are essential facilities for businesses that require space to store their inventory. One of the critical components of warehouse design is the aisle width, which determines the amount of space required to move products in and out of the storage area.

Forklift aisle widths are an essential consideration when planning and designing a warehouse. This article will provide an overview of different aisle widths, hw to calculate them, and the benefits of different forklift aisle widths.

How To Work Out Minimum Aisle Width Requirements

Calculating the minimum aisle width requirements is an essential aspect of warehouse planning. Factors to consider when calculating the minimum aisle width include the type of forklift being used, the height of the storage system, and the size of the products being stored.

Generally, the formula for calculating the minimum aisle width is:

Minimum Aisle Width = Forklift Clearance + Load Width + Pallet Overhang

While this is quite a simple formula, it is of course essential to accurately understand the dimensions of the goods that will be stored in your racking system.

Why It’s Important To Know Your Minimum Aisle Widths

It is essential to calculate minimum aisle widths for warehouse forklifts because it impacts the efficiency and safety of the warehouse operations. The aisle width is a critical factor in warehouse design and planning, as it determines the amount of space required for forklifts to manoeuvre within the warehouse.

Calculating the minimum aisle width ensures that forklifts can move safely and efficiently within the warehouse. If the aisle width is too narrow, forklifts may not be able to manoeuvre safely or may cause damage to the racking system or products. This can lead to delays in order fulfilment, increased maintenance costs, and potential safety hazards for workers and equipment.

On the other hand, if the aisle width is too wide, it can reduce storage density and increase operating costs. Wider aisles require more floor space, which can increase the overall size of the warehouse and, therefore, the rent or building costs. Wider aisles also require more travel time for forklifts, which can increase labour costs and reduce efficiency.

By calculating the minimum aisle width, businesses can optimise their warehouse layout and increase their storage density while still ensuring safe and efficient warehouse operations.

A qualified warehouse design professional can help determine the appropriate minimum aisle width for a specific warehouse layout and storage needs, taking into account factors such as the type of forklifts being used, the size and weight of the products being stored, and the overall storage capacity requirements.

Narrow Aisles

Narrow aisles are becoming increasingly popular in warehouses due to the benefits they offer in terms of storage density. They are typically 8 to 10 feet wide, which allows for narrow aisle forklifts to navigate.

This type of aisle is ideal for businesses that have limited space and need to maximise their storage capacity. Narrow aisles are commonly found in manufacturing plants and e-commerce warehouses.

Narrow aisle pallet racking is similar to wide aisle selective racking, but is installed so that there is less space between columns of racking. This type of racking system is designed to be used with specialised narrow aisle forklifts that can turn within the aisle. These forklifts are typically narrower than standard forklifts and have a higher reach capacity, allowing them to access pallets stored at greater heights. The narrower aisles allow for more racking systems to be installed in the warehouse, increasing storage density.

Narrow aisle racking systems can be designed to reach heights of up to 40 feet, maximising vertical storage capacity. The racking system is typically constructed with steel frames, with a series of beams and braces to support the pallets. These racking systems are designed to be flexible, allowing for adjustments to be made as the storage requirements change.

One of the main advantages of narrow aisle racking systems is their ability to maximise storage capacity while minimising floor space. By reducing the aisle width, more racking systems can be installed in the same floor space, increasing storage density. This can be particularly useful for businesses that have limited floor space or need to expand their storage capacity without increasing the overall size of their warehouse.

However, narrow aisle racking systems require specialised narrow aisle forklifts, which can increase the initial capital cost of the system. Additionally, the narrower aisles can make it more challenging for forklift operators to manoeuvre and may require additional training. A qualified warehouse design professional can help determine if a narrow aisle racking system is suitable for a specific warehouse layout and storage needs.

More About Narrow Aisle Pallet Racking

Very Narrow Aisles

Very Narrow Aisle (VNA) racking is a high-density storage system that utilises aisles that are typically 5 to 6 feet wide. These racking systems are designed to maximise storage capacity by optimising the available floor space, and can be used in warehouses with limited floor space.

The main advantage of VNAs is that they offer the highest storage density, allowing businesses to store more products in a smaller area. VNAs are typically found in high-density storage facilities, as well as automated storage and retrieval systems (AS/RS).

VNA racking systems are designed to be used with specialised narrow aisle forklifts that are wire-guided or rail-guided to travel along the narrow aisles. These forklifts can operate in the narrow aisles with great accuracy, reducing the risk of accidents and damage to the racking system. The wire or rail guidance system also helps to maintain the precise positioning of the forklift in the aisle.

VNA racking systems can be designed to reach heights of up to 40 feet, maximising vertical storage capacity. The racking system is typically constructed with steel frames, with a series of beams and braces to support the pallets. These racking systems are designed to be flexible, allowing for adjustments to be made as the storage requirements change.

One of the main advantages of VNA racking systems is their ability to maximise storage capacity while minimising floor space. With the use of wire-guided or rail-guided forklifts, these systems can be optimised to provide very high-density storage solutions. This can be particularly useful in warehouses with limited floor space, where maximising the use of vertical space is essential.

However, VNA racking systems require specialised narrow aisle forklifts and guidance systems, which can increase the initial capital cost of the system. Additionally, VNA racking systems may not be suitable for all types of products or storage requirements. A qualified warehouse design professional can help determine if a VNA racking system is suitable for a specific warehouse layout and storage needs.

Types of Forklifts Used in Warehouses

There are various types of forklifts used in warehouses, including:

Counterbalance forklifts
Reach forklifts
Order pickers
Pallet jacks

Counterbalance forklifts are the most common type of forklifts used in warehouses and are suitable for wide aisles.

Reach forklifts and order pickers are designed for narrow aisles, while pallet jacks are ideal for very narrow aisles. It's crucial to consider the dimensions of the forklifts when determining the aisle width.

Benefits of Narrower Aisles

Narrower aisles offer several benefits, such as increased storage capacity, improved efficiency, and reduced operating costs.

By reducing the aisle width, businesses can increase their storage density, which can save money on rent or building costs. Additionally, narrow aisles can improve efficiency by reducing the distance travelled by forklifts, which can increase productivity and reduce labour costs.

Increased Storage Capacity

One of the primary benefits of using narrower aisles in warehouses is that they allow businesses to store more products in a smaller area. This can be particularly useful for businesses that have limited space or need to expand their storage capacity without increasing the overall size of their warehouse.

Improved Efficiency

By reducing the aisle width, businesses can also reduce the distance travelled by forklifts, which can help improve efficiency and productivity. This can be especially beneficial in high-volume warehouses where fast and accurate order fulfilment is crucial.

Reduced Operating Costs

Narrower aisles can help businesses reduce their operating costs. By increasing storage capacity and improving efficiency, businesses can save money on rent or building costs, labour costs, and equipment maintenance costs.

Greater Flexibility

Narrower aisles can also provide greater flexibility for businesses. By using narrow aisle racking systems, businesses can adjust the width of the aisles to meet their changing storage needs. This can be especially helpful for businesses that experience seasonal fluctuations in demand or that need to store products with varying dimensions.

Improved Safety

While it may seem counterintuitive, using narrower aisles can actually help improve safety in the warehouse. Narrower aisles can help reduce the speed at which forklifts travel, which can help prevent accidents and collisions. Additionally, using narrow aisle forklifts can help reduce the risk of accidents in busy warehouses with high traffic volumes.

More Options For Increasing Storage Density

Increasing storage density is a common goal for many businesses that operate warehouses. Besides utilising narrower aisles, there are other options available to increase storage density, including:

Vertical Storage Solutions

By utilising the height of the warehouse, businesses can increase their storage capacity. Vertical storage solutions such as high bay pallet racking, automated storage and retrieval systems (AS/RS) and storage mezzanine levels can help maximise vertical space.

Double-deep racking

This system involves placing two rows of pallets back-to-back, which doubles the storage capacity of the warehouse. Double deep pallet racking can be a great way to enhance the storage density within a facility and is compatible with various aisle width configurations.

Drive In Racking

Drive-in racking systems allow forklifts to drive into the racking to access the products, which eliminates the need for aisles and maximises storage density. This type of system is popular in sectors where a first in last out process is used.

Push Back Racking

This system involves storing pallets on carts that slide along rails, allowing for more pallets to be stored in the same amount of space. Push back racking can be a highly efficient way for bulk storage of non-perishable goods.

Racking Solutions To Match Your Business Needs

Almost every business that uses warehouse space to store goods will use some type of racking, and it’s essential to use a racking and storage system that’s tailored to the type of goods stored, as well as the processes and workflows of the organisation.

Forklift aisle widths are an essential aspect of warehouse design and planning. The aisle width can impact the storage capacity, efficiency, and operating costs of a warehouse. By understanding the different types of aisle widths, forklifts, and storage solutions, businesses can optimise their warehouse layout and enhance their storage density.

Whatever type of goods you need to store, working with a specialist like Avanta means access to tailored solutions designed to meet the specific need and requirements of your business. This ensures you’re able to to maximise the potential of the space available within your facility for optimum safety, efficiency and performance.

From e-commerce warehouse solutions including high density storage, picking and packing and returns handling, to sophisticated racking and storage solutions for 3rd party logistics providers, we’ve got decades of experience working with clients in a wide range of sectors throughout the UK.

For more information about our services and to find out about the most suitable warehouse solutions for your business, get in touch with our team.

Contact Avanta