Safety and space efficiency? You cannot have one without the other in today’s warehousing environment. One solution that’s gaining traction across industrial facilities is the integration of warehouse walkways and walkovers - in other words, elevated structures that separate pedestrian access from busy work zones while making better use of available space.
Whether you're operating a large fulfilment centre with a mezzanine system or a more compact distribution hub, walkways offer a smart way to improve access, visibility and flow without having to completely redesign your warehouse layout.
This article explores how to successfully integrate walkways and walkovers into existing infrastructure. We will cover best practices for safe installation, optimal layout planning and long-term usability - all while avoiding costly disruption to operations.
Why integrate walkways into existing warehouse infrastructure?
We don’t need to tell you that warehouses are busy places. Forklifts, pallet jacks, pickers and packers are all moving in unison across shared zones. Without proper separation, this can create confusion, risk and of course - lost time. Here are some other key advantages of walkway integration:
Better warehouse safety:
Adding walkways provides dedicated pedestrian access, reducing the chance of collisions and improving site safety.
Increased accessibility:
They also help create more efficient travel paths for staff - particularly in facilities where floor-level congestion or machinery zones make navigation challenging.
Optimise use of space:
Walkovers, which bridge areas such as racking aisles, equipment zones, or mezzanine platforms, can also make use of vertical space that would otherwise go to waste. In facilities with limited floor area, this is a cost-effective way to expand operations without the need for relocation or major building work.
Put simply, integrating walkways and walkovers enhances warehouse safety, accessibility and spatial efficiency - without putting the brakes on your day-to-day operations.
Planning and design considerations
Before breaking any ground, it’s essential to plan carefully. Integrating walkways into an active warehouse environment calls for a clear understanding of your current setup - and identifying what you are wanting to improve.
Site assessment
Start with a full assessment of your warehouse layout. Identify high-traffic areas, pinch points and zones where foot traffic regularly intersects with vehicle paths. Check the structural load capacity of walls, mezzanines or other potential anchor points.
Compliance requirements
All walkway installations must adhere to relevant Australian safety regulations, including height, handrail and load-bearing standards under AS/NZS 1657:2018. These requirements ensure walkways are safe, secure and legally compliant.
Traffic flow optimisation
Avoid creating bottlenecks or awkward detours. Your walkways should complement existing workflows, not disrupt them. Consider how staff move throughout the facility and ensure new structures support (rather than compete with) those movements.
Height clearances and accessibility
Make sure walkways maintain sufficient clearance for forklifts, conveyor systems or tall stock. At the same time, consider access points: ramps, staircases or entry platforms must be designed to be safe and easy to use.
This is where working with a trusted specialist like Unistor can make all the difference. With decades of experience designing and installing walkways across complex warehouse environments, we know what works - and what to watch out for.
Types of walkways and their applications
Warehouse walkways and walkovers are not one-size-fits-all. Here’s a breakdown of common types and where they are most commonly used:
Overhead walkways
These offer elevated paths across high-traffic or machinery-heavy zones. They are ideal for separating pedestrians from forklifts or other mobile equipment, offering a clear line of sight across the warehouse floor.
Walkovers
Walkovers quite literally bridge the gap between different sections of your warehouse - whether it’s between two industrial mezzanine levels, across a conveyor line or above a packaging area. They are useful for creating safe shortcuts and improving internal connectivity.
Catwalks
These narrow, elevated walkways are often used for maintenance access to elevated equipment, control systems, or overhead utilities. They are usually positioned along the perimeter or between service areas.
Each of these structures can be custom-designed to fit your warehouse’s layout, workflow, and safety requirements - and Unistor can advise on the most effective configuration based on your current footprint and operational goals.
Best practices for integration
Done well, walkway integration should feel like a natural extension of your warehouse. Here are some key practices to ensure a smooth process:
Engage early with a specialist provider
Involve experts like Unistor from the planning stage. This helps identify the most effective layout, ensures structural compliance and reduces the likelihood of costly redesigns or delays.
Use modular, customisable systems
Modular walkway components allow for quicker installation, easier customisation, and better future scalability. They’re especially useful in active environments, where installations need to slot in around ongoing operations.
Slash downtime
Plan installation during quieter periods: overnight, on weekends or during scheduled maintenance windows. In some cases, walkways can be installed in phases, reducing disruption and allowing sections of the warehouse to stay operational.
Incorporate wayfinding and signage
Clear signage and colour-coded walkways help staff navigate the new layout safely. Visual cues reinforce usage rules and prevent confusion - especially in high-traffic zones.
Regular inspections and maintenance
Once installed, walkways must be inspected routinely for signs of wear, corrosion or damage. Load-bearing components, handrails and anti-slip surfaces should be used to promote long-term safety and compliance.
Unistor offers maintenance-friendly designs that make routine checks quick and straightforward - helping you stay compliant without adding unnecessary admin.
Conclusion
Integrating warehouse walkways and walkovers is one of the smartest moves a facility can make to enhance safety, improve flow and unlock underutilised space. Whether you're operating a sophisticated 3PL site or a modest warehouse with limited floorspace, the right walkway solution can transform your layout without major disruption.
But success starts with the right planning - and the right partner. With a track record of delivering practical, compliant and space-efficient mezzanine solutions across Australia, Unistor helps businesses future-proof their infrastructure while keeping operations running smoothly.
Get in touch to find out how we can help optimise your warehouse layout for safety, performance and growth.
