What is High Piled Storage

Many warehouse managers may have considered a storage method called high-piled storage when planning rack layouts.

But before adopting high-piled storage, I have a question for you: Do you truly understand what high-piled storage is? Do you know its design requirements, relevant regulations, and pros and cons?

If you’re unsure, let me guide you through everything you need to know about high-piled storage!

What is high piled storage?

High-piled storage is a storage method where items or goods are stacked to or above a specified height. The definition and height standards vary depending on national or regional regulations.

For example, in the United States, the International Fire Code (IFC) defines high-piled storage as systems with stacking heights of 12 feet (approximately 3.66 meters) or more. For highly combustible materials, such as paper or plastics, the height standard may lower to 6 feet (about 1.83 meters).

Other countries may have similar standards with slight variations.

Design Requirements for High-Piled Storage

High-piled storage design involves various considerations, including rack system design, fire safety, aisle planning, equipment selection, and operational safety. Key requirements include:

Space Planning

Storage Height

• Determine the maximum stacking height, considering building height limits and goods' stability.

• Height restrictions depend on:

• Fire regulations: Coverage and intensity of sprinkler systems.

• Goods characteristics: Weight, volume, and stability.

• Equipment capacity: Maximum lifting height of forklifts.

Aisle Width

• Main aisles: For machinery, typically 3.0 meters or more (based on forklift type).

• Secondary aisles: For personnel or emergency escape, at least 1.2 meters (per local fire codes).

Floor Load Capacity

• Floors must support concentrated loads from high-piled storage.

• Evaluate floor load capacity (e.g., kN/m²), especially beneath heavy racks.

Rack System

Rack Types

• Select suitable racks, such as:

• Pallet racks: Selective or drive-in racks.

• Automated systems: High racks with stacker cranes.

• Cantilever racks: For long or irregular items.

Stability

• Ensure seismic-resistant design, especially in earthquake-prone areas.

• Anchor racks with base bolts and add cross braces if needed.

Load Capacity

• Calculate maximum load per rack level to prevent overloading.

• Account for dynamic loads during loading and unloading.

Fire Safety

Sprinkler Systems

• Install automatic sprinkler systems compliant with fire codes. Design based on goods' combustibility (e.g., ordinary combustibles, flammables).

• Ensure sprinkler coverage and flow meet stacking height requirements.

Smoke Detection

• Install detectors in areas obscured by high-piled goods.

Fire Barriers

• Add fire barriers or walls for materials like plastics or wood.

Emergency Access

• Provide sufficient emergency evacuation routes with clear signage.

Equipment

Mechanical Equipment

• Choose equipment based on storage height, such as:

• Reach trucks.

• Automated guided vehicles (AGVs).

• Automated stacker cranes.

Safety Features

• Use fall protection, guardrails, and warning signs for high-level operations.

• Ensure stability and safe handling of high-piled goods.

Operational Safety

Training

• Train staff in operating equipment, fire emergencies, and stacking rules.

Regular Inspections

• Check rack structures, fire equipment, and operational devices periodically.

Anti-Tip Measures

• Install anti-tipping nets, guardrails, or other barriers in high-piled areas.

Regulations and Standards

Local Regulations

• Comply with local building codes, fire codes (e.g., IFC, NFPA 13), and safety standards.

International Standards

• Refer to standards such as:

• ISO 283: Rack system design.

• EN 15620: Tolerances, deformations, and clearances for industrial racks.

These considerations ensure the safety, efficiency, and compliance of high-piled storage systems.

Standards and Regulations for High-Piled Storage

High-piled storage systems must adhere to various standards to ensure safety, functionality, and compliance. Key areas include fire safety, rack structure design, operating environments, and safety protocols.

Fire Safety Standards

International Fire Code (IFC)

• Defines height standards for high-piled storage:

• Ordinary goods: 12 feet (approx. 3.66 meters) or higher.

• Highly combustible goods (e.g., plastics): 6 feet (approx. 1.83 meters) or higher.

• Requires appropriate automatic sprinkler systems with specified intensity and coverage.

National Fire Protection Association (NFPA)

• NFPA 13: Covers design and installation of sprinkler systems, including density and distribution.

• NFPA 30: Addresses storage and protection of flammable liquids.

• NFPA 101: Life safety code, detailing evacuation routes, emergency exits, and escape guidance.

Local Regulations

• China: Code for Fire Protection Design of Buildings (GB 50016).

• Europe: EN 12845, the standard for automatic sprinkler systems.

Rack Structure Design Standards

ISO International Standards

• ISO 283: Structural stability and load testing for rack systems.

• ISO 15629: Safety requirements for rack usage.

• ISO 15620: Specifies tolerances, deformations, and clearance for racks.

European Standards

• EN 15512: Strength and structural design for steel racks.

• EN 15635: Usage and maintenance of rack systems, emphasizing inspections.

China National Standards

• GB/T 33411-2016: Design, manufacturing, and acceptance standards for warehouse racks.

• JGJ 81-2016: Seismic design specifications applicable to high racks.

Operational Environment Standards

Lighting

• Adequate illumination in storage areas:

• EN 12464-1: Lighting standards for workplaces.

• China’s Standard GB 50034: Minimum lighting requirements for storage areas.

Ventilation and Temperature/Humidity Control

• Follow specific standards based on stored goods (e.g., food, pharmaceuticals):

• ISO 22000: Food safety management systems.

• GMP: Pharmaceutical storage standards.

Operational Safety Standards

Mechanical Equipment

• Equipment selection and operation must meet:

• ISO 3691-1: Design and operation requirements for industrial trucks.

• ANSI/ITSDF B56.1: Forklift safety standards.

Personnel Safety

• Operators should receive professional training and follow:

• OSHA 1910.176: Warehouse operation safety standards.

• China’s GB 5083: Standards for production safety and protection design.

Anti-Tipping Devices

• EN 15635: Requires anti-tipping nets, collision protectors, and supporting structures.

Other Relevant Standards

High-Level Storage Efficiency

• ISO 14738: Ergonomic standards for comfortable and efficient high-level operations.

Fire Barriers

• NFPA 221: Design requirements for firewalls and barriers.

Environmental Impact

• ISO 14001: Environmental management standards for storage systems.

Key Focus Areas in Design and Implementation

• Ensure compliance with all fire safety and rack design regulations.

• Choose rack types and materials suited to the characteristics of stored goods.

• Plan for standard-compliant aisle widths, rack stability, and operational equipment.

These guidelines provide a comprehensive foundation for high-piled storage system planning and operation.

Advantages and Disadvantages of High-Piled Storage

Advantages

High Space Utilization

• Maximizes Vertical Space: Increases storage capacity by utilizing vertical warehouse space, reducing floor area requirements.

• Ideal for High-Density Storage: Best suited for storing large quantities of fewer types of goods.

Cost Efficiency

• Saves Land Costs: Accommodates more goods in the same warehouse area, reducing the need for facility expansion.

• Supports Automation: Works well with automated equipment (e.g., stacker cranes, AGVs), reducing labor costs.

Strong Flexibility

• Adaptable for Various Goods: Suitable for palletized, bulk, or long-shaped items.

• Modular Design: Systems can adjust height and layout as needed.

Improves Logistics Efficiency

• Fast Access: Paired with high-reach forklifts or automation, it reduces retrieval times.

• Effective Inventory Management: Supports FIFO and LIFO inventory strategies.

Disadvantages

High Fire Safety Requirements

• Complex Fire Systems: Requires high-intensity, wide-coverage sprinkler systems, increasing costs and complexity.

• Regulatory Constraints: Strict adherence to fire safety standards (e.g., NFPA 13, IFC) limits design flexibility.

Operational Challenges

• Heightened Work Risks: Specialized equipment for high-altitude operations increases complexity and safety risks.

• High Equipment Costs: Initial investment in high-reach forklifts, stacker cranes, or automated systems is substantial.

Increased Safety Demands

• Rack Stability Issues: Higher stacking can cause instability and tipping risks, especially in seismic zones.

• Complex Maintenance: Regular inspection and upkeep of racks and equipment incur additional costs.

Limited Flexibility

• Low Adaptability to Changes: Once rack height and layout are set, adjustments for changing inventory needs are challenging.

• Dependence on Goods Shape: Irregularly shaped items may require custom storage solutions.

Applications of High-Piled Storage

Large-Volume Single Goods Storage

• Suitable Industries: Logistics centers, large factories, retail distribution hubs.

• Characteristics: Few product types but large quantities, such as food, beverages, and electronics.

• Advantages: Optimizes inventory management by storing large volumes of similar goods, reducing land and operational costs.

Automated Warehousing

• Suitable Industries: E-commerce logistics, pharmaceutical sector, high-tech manufacturing.

• Characteristics: Integrated with automated systems like stacker cranes, AGVs, or shuttles for efficient operations.

• Advantages: Enables 24/7 operation, minimizes manual intervention, and enhances logistics efficiency and inventory accuracy.

Cold Chain Storage

• Suitable Industries: Food processing, pharmaceutical sector, biotechnology.

• Characteristics: Requires storage of large volumes in refrigerated or frozen conditions while maximizing space utilization.

• Advantages: Reduces cold storage space requirements, lowering operational costs for temperature control systems.

Conclusion

By now, you should have a clear understanding of high-piled storage and its potential fit for your needs. If you're still deciding whether to adopt it, consider your storage requirements and operational goals.

For further inquiries or customized storage solutions, feel free to contact us!