{"id":3217,"date":"2013-05-31T16:25:29","date_gmt":"2013-05-31T21:25:29","guid":{"rendered":"http:\/\/www.cisco-eagle.com\/blog\/?p=3217"},"modified":"2025-12-27T12:53:40","modified_gmt":"2025-12-27T18:53:40","slug":"key-considerations-for-warehouse-aisle-widths","status":"publish","type":"post","link":"https:\/\/www.cisco-eagle.com\/blog\/2013\/05\/31\/key-considerations-for-warehouse-aisle-widths\/","title":{"rendered":"Key Considerations for Warehouse Rack Aisle Widths"},"content":{"rendered":"

\"warehouse<\/p>\n

Forklift aisle widths are typically set when pallet racking<\/a> is installed. In many cases, such as narrow aisle projects, these spaces are critically important. Typically, warehouse managers don’t attempt to lay out these types of storage facilities. But for reach truck, selective rack applications, these aisle sizes are often “eye balled,” or given a 12′ width no matter what type of forklift is using the aisles. If you are laying out a facility, what criteria should you use for rack aisle width?<\/p>\n

<\/p>\n

When laying out your warehouse out, you must balance conflicting goals<\/h3>\n
    \n
  1. \n

    Narrower aisles<\/strong> that optimize space, allowing for more storage positions in the same space<\/em><\/p><\/blockquote>\n<\/li>\n

  2. \n

    Wider aisles<\/strong> that are safer and help forklift drivers maneuver, reducing collision risks<\/em><\/p><\/blockquote>\n<\/li>\n<\/ol>\n

    With forethought and the right equipment, you can balance these two goals.<\/strong> You’re generally dealing with two types of aisles:<\/p>\n

    Traditional counterbalance forklift aisles<\/h4>\n

    The tried and true counterbalanced forklift needs about 12 feet to safely allow for picking and placing pallets. The forklift must have room within its turning radius to drive through, back up and access the rack on either side of the aisle. Many warehouses are laid out based on the traditional wide-aisle standard, and are set to 12 feet, whether or not that’s the optimum space. Newer forklift types can operate safely with narrower aisles.<\/p>\n

    Narrow aisle & very narrow aisle systems<\/h4>\n

    Narrow aisle vehicles don’t require as much space as conventional lift trucks, which allows you to narrow your aisles to increase storage density without compromising safety.\u00a0 These systems rely heavily on the turning radius and maneuverability of the forklift.<\/p>\n

    General aisle configuration guidelines<\/h3>\n

    \"\"<\/p>\n

    Typical aisles for 3 or 4 wheel, counterbalance forklifts are wider than for other types of trucks. Here’s a simple rule of thumb calculation:<\/p>\n

    \"pallet<\/p>\n

      \n
    1. Measure the head length:<\/strong> the distance from the back of the forklift to the front of the load back rest.<\/li>\n
    2. Measure load length:<\/strong> the length of the pallet plus its load overhang.<\/li>\n
    3. Add<\/strong> the head and load lengths together.<\/li>\n
    4. Add at least 12\u201d maneuvering space:<\/strong> remember to add a minimum 6\u201d for pallet load overhang from the rack on each side of the aisle\u2014or more if you typically need it. Wider aisles help drivers avoid backing into racks, but also consume space.<\/li>\n
    5. Add all together for the minimum width for a typical counterbalanced forklift.<\/strong> Remember<\/span> that this is only a guide and that most forklifts come with detailed aisle width specifications.<\/li>\n
    6. Know your forklift turning radius<\/strong> to ensure drivers can easily access pallets without risk of striking racks.<\/li>\n<\/ol>\n

      \"forklift<\/p>\n

      Always consult your forklift documentation when making these determinations<\/h4>\n

      These calculations work for standard forklifts in selective rack applications. For narrow or very narrow aisle racks, the forklift you’re using determines aisle widths. Many lift truck manufacturers have calculations designed for their vehicles. Also, for more complex rack design, consult us, or another qualified racking company for assistance.<\/p>\n

      Matching your rack, processes, layout and forklift makes your operation faster, safer and better optimized for space. Always install\u00a0 frame protectors<\/a> to prevent damage in case of collisions.\u00a0<\/em><\/p><\/blockquote>\n

      Typical rack aisle width requirements for lifting equipment<\/h3>\n

      \"\"<\/p>\n

      \n

      Forklift types and rack aisle width<\/h3>\n

      To fully understand whether or not you can narrow your aisles to save space, you should have a full grasp of the type of forklifts in use. If your aisles utilize more than one type of forklift, then the aisle must be wide enough to tolerate the maneuver of all machines in use.<\/p>\n

      Sit-down counterbalanced<\/span><\/h4>\n

      The most common forklift in the world. It needs plenty of operating space\u2014at least 12 feet. Include the amount of space taken by column protectors or loads that extend beyond the beam on the floor or the first level of the rack.<\/p>\n

      Stand-up single-reach<\/span><\/h4>\n

      These lifts can operate in even less space than deep reach models\u2014as little as 8 feet due to shorter forks.\u00a0<\/span><\/p>\n

      Stand-up deep-reach<\/span><\/h4>\n

      Built for narrower aisle operations of 9 to 11 feet. The reach of the forks and the fact that operators require less space allow narrower aisles than for sit-down trucks.<\/p>\n

      Turret or swing-mast narrow aisle<\/span><\/h4>\n

      Because the forks can pivot 90\u00b0, these lifts don\u2019t turn to face rack aisles. Aisles can be less than 5\u20196\u201d.<\/p>\n

      Narrow-aisle order picker<\/span><\/h4>\n

      Use the least space\u2014between 4 and 5 feet\u2014since the operator usually walks behind the lift.\u00a0<\/span><\/p>\n<\/div>\n

      <\/h3>\n

      Pedestrian safety and forklift aisles<\/h3>\n

      When people are present in forklift aisles, aisle width design is even more important.\u00a0<\/span>Transit aisles or 1-way aisles should have defined pedestrian lanes of no less than 3.3\u2019 wide.\u00a0<\/span>For working\/picking aisles, add the same 3.3\u2019 pedestrian lane. Add more space to the load overhang to increase passage width since two sides of the aisle must be considered.<\/p>\n

      Tunnel lanes (underpasses) should not be used by both pedestrians and forklifts. Keep these passages separate as visibility and maneuvering space are even tighter than in picking and transit lanes.<\/p>\n

      Other rack configuration resources<\/h4>\n