Modern warehouses are built taller than ever. It makes sense: building tall maximises usable space and increases the functionality of the site without the need to expand the footprint.
As a result, businesses are often swimming in vertical warehouse space. Unfortunately owners and leaseholders haven’t got the memo, because in most warehouses much of this space remains unutilised.
The good news? This presents an opportunity to unlock serious vertical value through cleverly built warehouse structural systems. By building up a business can avoid expensive expansion and relocation while enhancing inventory management, order fulfilment and throughput.
At Unistor we specialise in the construction of warehouse mezzanine solutions and other multi-tier warehouse structures that help you capitalise on this opportunity.
In this guide we’ll share our expertise on how to maximise warehouse headroom utilisation, by exploring the whats, whys and hows of vertical warehouse infrastructure.
The case for designing up, not out
Space is at a premium in modern Australian cities. As the cost of industrial land continues to rise, businesses are under pressure to make the most of what they’ve got, as extra floorspace is a) hard to come by and b) expensive to secure.
The solution is simple: don’t build out, build up.
Warehouse heights are capped based on safety considerations, most notably sprinkler coverage. In 2017 new Australian Standards were introduced that increased maximum ridge heights from 13.7m to 14.6m. As a result, businesses are enjoying greater warehouse volumes than ever before.
Warehouse layout optimisation is about better utilising the top half of your premises, leading to greater efficiency, higher throughput, and the huge savings from avoiding expensive expansion or relocation.
By installing mezzanines, you can essentially turn your warehouse into a multi-storey building. And by integrating warehouse automation technologies, you can enhance your operational efficiency too.
Structural systems that deliver vertical performance
There are a number of warehouse structural systems that are designed to enhance how you use your vertical space. At Unistor, for example, we offer the following custom offerings:
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Mezzanines: Construct multiple levels within your warehouse – space that is perfect for storing parts and smaller inventory, or creating usable workspaces for fulfillment or admin.
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Raised platforms: A lightweight and modular version of a mezzanine, raised platforms are ideal for automation support, staging or storage.
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Walkways/catwalks: Designed for safe worker movement and maintenance access.
By integrating automation within your warehouse platform design, you can further enhance the safety, efficiency and productivity of your facility through the use of AGVs, AS/RS and conveyors.
Design considerations for architects and designers
What elements of a vertically optimised warehouse should you account for when designing your new space? Key considerations include:
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Load capacity planning to ensure the structural integrity of the system
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Safety considerations like sprinklers, fire escapes, lighting and ventilation.
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Floor finishes, structure heights, and any necessary access ramps and lifts.
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Integration with building services (plumbing, power, HVAC, data).
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Integration with warehouse automation technologies (AGVs, AS/RS, conveyors).
When you choose a quality warehouse optimisation partner like Unistor, you can feel safe in the knowledge that all relevant elements have been considered, and your space will be optimised and enhanced based on your specific needs.
Unlocking value across use cases
What does vertical warehouse design look like in the real world? Here are just a few of the ways that we’ve helped businesses better utilise their space at Unistor:
Logistics: Separate workflows vertically to streamline operations
We designed and built automation support structures and access systems for Cardinal Logistics, operators of New Zealand's largest automated warehouse. We created vertical, separated workflows that maximised the use of space within a highly congested environment.
Cold storage/pharma: Build temperature-controlled upper zones
We helped medical equipment manufacturer Medilogic create 360m² of extra operational space, including temperature-controlled zones, with a modular mezzanine floor for use as both extra storage and additional operational space.
E-commerce warehousing: Create high-speed order fulfilment layers
We created a modular, double-story sortation table structure for Kmart, which covered 5000m² and included operator platforms and machine guard fencing, creating space for fast fulfillment.
Urban Logistics: Build up in footprint-constrained city sites
We helped No Birds multiply their storage space without moving from their Mascot site, by installing three elevated parking structures that added 3000m² of extra parking space for their rental vehicles.
Compliance and certification in vertical structures
There are a few key compliance considerations that come with developing any warehouse optimisation solution. All enhancements need to have all necessary engineering documentation to gain CDC approval and meet Australian Standards.
A few key considerations in terms of compliance include load bearing requirements, fire regulations, access, egress, lighting and visibility.
In terms of vertical space utilisation, ceiling clearance is another critical factor, as you need to ensure sprinklers offer the necessary coverage, and collisions are avoided.
At Unistor we take care of all this for you through our principal contractor model. We design, engineer, certify and install your mezzanine, with minimal (often zero) downtime. Your job is simply to run your business, safe in the knowledge that a new and improved way of working is being prepared.
Capitalise on vertical space with Unistor
The answer to your space needs could be hovering right above your head. And if you’re considering space-maximising or space-saving warehouse upgrades, look no further than Unistor.
Our expert team brings decades of combined experience in delivering tailored mezzanine solutions.
Warehousing, distribution, logistics, fulfilment; whatever your needs, wants or situation, we’ll help you optimise your use of vertical space. Our end-to-end service covers design, certification, installation and project management, with every build customised to the precise operational needs of the client.
The earlier we are engaged, the better the outcomes tend to be. But no matter how established your warehouse is, or how much of a transformation you’re looking to undertake, we can take care of it all, as the principal contractor responsible for all structural works.
Ready to make the most of all that vertical space? We’re ready to help.
Get in touch with our expert team today for a feasibility assessment or design consultation.
