Summary
For a safe and efficient warehouse, you need a comprehensive understanding of all rack types , their static and dynamic load-bearing capacity, precise safety standards, automated systems, and realistic testing methods. This guide provides a comprehensive overview—ideal for decision-makers and specialists alike.
System overview: Modern shelving types in comparison
Drive-in and drive-through racks
With drive-in/drive-through racking, forklifts drive directly into the racking bay and place pallets on guide rails. The difference: Drive-in racking operates according to LIFO (Last In, First Out), while drive-through racking operates according to FIFO (First In, First Out).
Technical features:
- Guide channels and pallet rails for correct guidance
- Side-seated forklift or special forklift required
- High space utilization, but limited direct access
- Tight tolerances in flatness, construction accuracy and tolerances
Mobile shelving systems
Mobile racks consist of shelves that move on motorized or mechanical carriages. Only one aisle is open, while the rest are pushed together.
Key features:
- Capacity increase often 80% to 120% compared to static shelves
- Drive by electric motor or chain/gear mechanism
- Integrated safety technology: gear locking, end stops, backstops
- Retrofitting possible for existing shelving structures
Automatic small parts warehouses (ASW) / shuttle and stacker crane systems
These systems completely automate material flow. There are two main variants:
- Storage and retrieval machines (SRM): automatic bridge or crane racks that operate in high shelves.
- Shuttle systems: autonomous units that transport pallets or containers within the racking area.
Special features:
- Heights up to 25 m or more possible
- Redundant systems (backup axes, buffers)
- High investment costs, complex maintenance
- Excellent throughput and space utilization
Complementary systems & special solutions
- Push-back / multi-depth systems: Pallets are stacked backwards.
- Live pallet storage / flow racks: with roller conveyors for FIFO management.
- Cantilever racks: ideal for long goods (pipes, profiles). Requirements for wind loads and cantilever statics increase with height and length.
- High-bay warehouses / silo buildings: The racking structure directly forms the building envelope, and loads are transferred to the foundation.
Safety & Standards – in depth
DIN EN 15512 & related regulations
The DIN EN 15512 standard regulates adjustable steel pallet racking, but does not cover all modern systems (e.g., drive-through, mobile racking, shuttles). Planning must fill these gaps with specific regulations.
Important extensions and test assumptions:
- Horizontal loads: For shelves over 6 m high, a horizontal load of 0.25 kN at the top and 0.50 kN up to a height of less than 3 m is assumed.
- Lifting forces: Plug-in connections and supports must withstand a lifting force of at least 5 kN.
- Tolerances: Alignment deviations, vertical alignment and distortions according to EN 15620.
Collision protection & anti-lift protection
Shelving systems inevitably require protection against forklift impacts and the unintentional lifting of beams:
- Collision protection: minimum height 400 mm.
- Anti-lift protection: Connecting elements (e.g. beam connections) must withstand at least 5 kN.
- Rack classes / height classes: From 12 m height, stricter requirements apply regarding bracing and horizontal load assumptions.
Damage assessment & traffic light system
A traffic light system should be used for inspection processes:
- Green: Deviations e.g. ≤ 3 mm transverse / ≤ 5 mm longitudinal per 1 000 mm – observation recommended.
- Orange: Limits exceeded – partial load, immediate repair or restriction.
- Red: Limit significantly exceeded – **Closure** and immediate repair necessary.
Every inspection must be documented – with inspection stickers, photo documentation and the designation of the competent person (according to DIN EN 15635).
Forklift & shelving system: Interaction in detail
Shelf clearances & safety distances
Precise clearance dimensions in the X, Y, and Z directions must be calculated:
- X-clearance: Distance between pallet edge and shelf support.
- Y clearance: Distance between load units and the carrier.
- Z clearance: Air gap above the highest pallet to the next component or ceiling.
For forklifts: ≥ 500 mm distance to the shelf wall, top edge of the top compartment at least 200 mm below maximum lifting height.
Dynamic forces, point loads & impact factors
Dynamic actions must not be directly integrated into static load assumptions:
- Point loads during settling can reduce the permissible shelf load by up to 50%.
- Impact factor according to VDI 2199 usually 1.4.
- Horizontal forces due to collision or side impact must be taken into account.
Calculation formula for surface load
q vertical = (G stacker + G load ) × shock factor / A wheel contact
Advanced tables & checklists
Comparison table: Shelf types & features
| Shelf type / system | access | Main advantages | Restrictions / Requirements | Is automation possible? |
|---|---|---|---|---|
| Pallet rack (classic) | Direct access | Modular, proven | Wide aisles required, space required | Yes (RBG integration) |
| Drive-in/drive-through rack | Partial direct access | High space utilization | Restricted access, tolerance requirement | Yes (RBG, control) |
| Mobile shelving | Direct access to every pallet | Maximum use of space | Mechanically complex, safety technology required | Partially automated |
| AKL / Shuttle / RBG | Automatic access | High throughput, space optimization | High costs, complexity | Fully automated |
| Cantilever rack | Direct access | Ideal for long goods | Wind loads, special statics | Hardly automatable |
| Pallet live / flow rack | FIFO access | High turnover | Mechanical effort, kinetic energy | Limited automation |
Safety and minimum dimensions
| feature | Minimum size / requirement |
|---|---|
| Collision protection height | ≥ 400 mm |
| Anti-lift device | ≥ 5 kN |
| Horizontal loads (shelf > 6 m) | 0.25 kN at the top, 0.50 kN up to 3 m height |
| Tolerance vertical alignment | ≤ H / 350 |
| Safety distance forklift to shelf | ≥ 500 mm (wide aisle) |
| Distance top compartment to lifting height | ≥ 200 mm |
Checklists for inspection & maintenance
Weekly visual inspection (warehouse staff):
- Check for damage to supports and trusses
- Inspect for distortions or kinks
- Check that fasteners are tight
- Detect corrosion damage / paint damage
- Check floor anchors for tightness
Annual expert inspection (qualified person):
- Load measurement & deflection of trusses
- Measurement of distortions / vertical alignment
- Checking plug connections / screws / connecting parts
- Testing of collision protection, anti-lift devices and system protection
- Documentation: test reports, photo evidence, stickers with date & name
Integration of modern forklift technologies
Guidance technology & narrow aisle systems
Narrow aisle systems utilize mechanical or optical guidance systems (e.g., laser rails, magnetic guides) for precise tracking. This allows aisle widths of approximately 1,600–2,000 mm to be achieved. Lateral forces are reduced by precise guidance.
Assistance and sensor systems (VDI 4482 and similar)
Modern forklifts increasingly feature:
- Distance sensors and collision warning systems
- Camera assistance for navigation in narrow aisles
- Load detection, lifting monitoring, warning systems
- Security areas and logic systems that regulate movements
High-lift technology & special masts
For lifting heights over 12 m, special mast solutions are required – telescopic, multi-joint, or profile systems. These require additional static assumptions:
- Wind loads and horizontal loads
- Side pressure from dynamic forklift traffic
- Stiffening and reinforced profiles at high altitudes
Practical examples and TCO considerations
To better understand the performance of modern storage and shelving systems, it's worth looking at real-life applications. The following anonymized practical examples demonstrate how different industries use automated systems to significantly increase efficiency, space utilization, and process quality.
Automotive industry: vertical lifts and automated shuttle systems
An international automotive supplier in southern Germany replaced conventional shelving with a vertical storage lift system for buffering production parts and time-critical components. The system, with over 12,000 bins, uses a pick-by-light system and increased picking performance by 35% .
Another example from automotive production demonstrates the integration of a pallet racking system with an automated shuttle into an existing manufacturing and ERP landscape. The solution offers:
- 5,000 pallet spaces
- Direct loading from the production line
- Reduction of delivery times by 20%
E-commerce: Warehouse lifts for fulfillment and returns management
A fulfillment service provider in the fashion and footwear sector consolidated several external warehouses into a central logistics hall with ten vertical storage lifts (37 trays each). The automated solution enables the picking of up to 1,000 orders daily in just 1,000 m² of warehouse space. Ergonomic workstations and shorter routes reduced throughput times by 40% .
Food wholesale: combination of classic and automated
A food and beverage wholesaler relies on a combined solution consisting of:
- Pallet racks with around 3,200 storage spaces
- Shuttle systems for high-speed machines and picking zones
- Roller conveyors between goods receipt, picking and shipping
The result: a 25% higher picking rate with simultaneous space optimization – 6,500 m² instead of the original 9,000 m² of storage space.
Focus on profitability: Total Cost of Ownership (TCO)
Automation isn't just worthwhile in day-to-day use—it also offers significant long-term benefits when all costs are taken into account. The following examples demonstrate how companies have achieved sustainable savings through targeted investments.
AGV instead of manual industrial trucks: Costs over 10 years
A manufacturing company compared twelve automated guided vehicles (AGVs) with six manual electric industrial trucks (HHWs) over a period of ten years:
- Personnel costs per year: AGV: €60,000, HHW: €660,000
- Cumulative savings: over €3.6 million (approx. 50%)
- Leasing model for AGVs: additional €215,000 savings through modular installments
External TCO analysis: Optimization before system implementation
A medium-sized consumer goods logistics company commissioned an external TCO analysis prior to implementing an automated order picking system (investment volume: €2.4 million). The analysis revealed, among other things:
- Hidden IT and restructuring costs
- Production downtime during implementation
Through targeted adjustments we were able to:
- operating costs reduced by 18%
- the error rate reduced by 25%
- employee satisfaction increased by 12%
- additional scaling without follow-up investments
Conclusion & practical recommendation
A warehouse is a complex system: Only those who consider shelving and forklift technology, automation, and inspection processes holistically can achieve efficiency and safety. Modern systems such as mobile shelving or automated small parts warehouses offer enormous added value – but only if they are technically sound and planned in compliance with standards.
Forklift rentals are flexible at BIBERGER
Do you want to cover seasonal peaks or temporarily expand your capacity? At BIBERGER, you can rent forklifts and warehouse equipment flexibly, tailored to your needs in logistics, production, or retail. Just contact us.
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The subject content on biberger.de are editorially created, reviewed, and continuously updated. The basis is our daily work with aerial platforms, telehandlers, and industrial trucks – in rental, sales, operational planning, and technical support.
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