The Challenge: Working within fixed boundaries
Many warehouses face the same dilemma: a footprint that cannot grow and internal fixtures that dictate the floor plan.
Building on a successful partnership from previous store fit-outs, this client returned to us with a more complex challenge. While our earlier work focused on standard high-density storage, this project required engineering around restricted access points, floor-mounted obstructions, and a variable-height sloping ceiling. The goal was to house 500 tyres in a space that most would have considered dead zone.
The Strategy: Adaptive Engineering
The solution required moving away from off-the-shelf racking toward a site-specific design. By prioritising vertical space rather than footprint, we implemented SSI Schaefer I600 Pallet racking to achieve:
- Custom Vertical Integration: Racking frames were precisely engineered to match the building’s slope and navigate internal bracing, reclaiming dead space near the ceiling.
- Modular Adjustability: Using beams adjustable in 50mm increments allowed the system to adapt to varying tyre sizes, ensuring no vertical space was wasted between levels.
- MHE synchronisation: When racking height exceeds standard levels, safety and speed must be synchronised. By working directly with MHE (Material Handling Equipment) partners during the design phase, we ensured that the safety cage and forklift reach were perfectly calibrated to the racking layout from day one.
The Outcome
By prioritising height and beam flexibility, the final capacity reached 600+ tyres. For businesses in the automotive or logistics sectors, this demonstrates that architectural flaws like sloping roofs or floor fixtures don’t necessarily have to limit inventory potential.
