Project Background
The client is a mid-sized building materials trading enterprise based in Brisbane, Australia, mainly supplying steel sections, pipes, aluminium extrusions and other long-profile construction materials for local contractors and retail merchants.
Core Client Pain Points
Through remote warehouse assessment, our technical team sorted out four key operational pain points of the client’s original ground stacking storage mode:
1. Low space utilization: The warehouse features an effective height of 6 metres, yet full ground stacking caused severe waste of vertical space. Standard customized racking solutions can boost warehouse space utilization by over 35%.
2. Low picking efficiency: Disordered ground stacking made product identification and access difficult. Staff spent 20–30 minutes on average retrieving specific materials, delaying order delivery and raising labor costs.
3. Chaotic inventory management: Without standardized storage classification, inventory counting was labor-intensive, counting errors occurred frequently, and irregular stacking easily led to material damage.
4. Hidden safety hazards: Unfixed stacked long-profile materials were prone to toppling, bringing slip and fall risks and major workplace safety threats.
Core Project Requirements
The client put forward clear customized specifications for racking design and delivery:
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Requirement Item
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Detailed Specification
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Stored goods
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Steel sections, pipes, aluminium profiles
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Material length
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3 m – 9 m
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Single arm load capacity
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800 kg – 1,000 kg
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Warehouse available height
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Approx. 6 m
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Operation mode
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Forklift handling + manual picking
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Design priority
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Maximize floor utilization, reserve unobstructed forklift aisles
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Delivery terms
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DDU Port of Brisbane
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Solution Development Process
The project lasted 5 weeks from early April to late May 2026, with iterative design and repeated communication to finalize the optimal customized solution:
Round 1 (Early April): Conduct demand research on client’s product specifications, warehouse size and operational workflow, and deliver the initial cantilever racking design scheme.
Round 2 (Mid–Late April): Optimize upright height and arm length based on client feedback, propose two layout plans, and refine aisle width and material zoning details.
Round 3 (Mid May): Confirm the hybrid layout of double-sided and wall-mounted single-sided cantilever racks, and finalize all technical parameters and production schedules.
Final Confirmation (Late May): Complete contract signing and confirm DDU delivery terms and project timeline.
Final Racking Solution & Layout Design
Racking Core Specifications
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Parameter
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Specification
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Upright material
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Q235B hot-rolled H-section steel
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Upright height
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6,000 mm
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Arm material
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Cold-formed steel
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Arm length
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1,200 mm / 1,500 mm (custom zoned)
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Rated load per arm
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1,000 kg
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Vertical adjustment pitch
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100 mm
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Surface treatment
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Electrostatic powder coating
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Assembly method
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Full bolted modular assembly
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Warehouse Layout Plan
Covering a warehouse area of 1,200 ㎡ with an effective height of 6 m, the layout adopts a hybrid structural design: four rows of double-sided cantilever racks are arranged in the central area with 3.5 m operation aisles; wall-mounted single-sided cantilever racks are installed on both sides to make full use of edge space. Materials are classified and stored by length (below 3 m, 3–6 m, 6–9 m), with a 4 m wide main aisle reserved to support two-way forklift traffic, realizing standardized and efficient storage management.
Project Effect
After the completion of the project transformation, the client’s vertical warehouse space is fully utilized, the overall space utilization rate is significantly improved, and material picking and inventory counting efficiency are greatly optimized. The standardized classified storage effectively reduces material damage rates and eliminates stacking safety hazards, helping the client realize refined and safe warehouse operation management.
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