Bespoke carpet racking solution
Designer Contracts Ltd were looking to maximise capacity and maintain operational efficiency at their new Kettering facility, so SEC Storage firstly set about reducing the aisle width where possible considering the use of reach truck forklifts with a bespoke carpet boom.
However, upon detailed space planning it was discovered that reducing aisles provided no additional storage capacity when considering the double entry carpet racks would measure a total of 10.2 metres in depth.
Increasing the aisle to 7.5 metres wide still enabled the optimum layout whilst providing greater space and therefore operational efficiency for the materials handling equipment.
SEC found that a 3700mm clear entry beam would offer optimum capacity and space utilisation for the installation. With four main SKU sizes, this clear entry would enable Designer Contracts to store any SKU, on any beam. 22mm thick chipboard was installed on specially designed step beams, minimising load inteference and increasing safety.
Not only was the installation phased but so was the delivery of materials which was crucial to the success of the handover. This meant no materials were stored on site taking up valuable space. The materials were delivered only when they were required.
During the design phase it was discovered a number of fire exits still needed to be accessed. Instead of reducing the entire bay width to allow access, SEC raised the first beam level to over 2.5 metres enabling pedestrian access and then designed a "stub frame" which would still enable the storage of carpet and vinyl beside it.
The overall installation is now able to store over 7,000 rolls of product overall, in addition to traditional pallet racking for goods such as laminate flooring and installation materials.
Safety netting was also supplied to the traditional racking structures, whilst a wire mesh gate and mini storage garages were installed to further segment product areas.