Case Study: Maximize Storage Capacity with High-Density Mobile Systems
Case Study: Maximize Storage Capacity with High-Density Mobile Systems
Table of Contents
Project Overview
Client: Leading Precision Manufacturer
Location: Springfield, New Jersey
Project Completion Date: September 2024
In March 2024, a leading precision manufacturer approached Storage Coordinators, Inc. seeking a high-density mobile storage system for a newly constructed stockroom situated on a structural mezzanine (sometimes referred to as freestanding or industrial work platforms) that was recently installed. The client required a High-Density Mobile Shelving System to maximize their available storage space while ensuring ease of access for their operations.
The client’s stockroom was designed to store a wide variety of bins and boxes of all different sizes, necessitating a storage solution that not only maximized capacity but also allowed for smooth operational flow with use of their rolling carts. With their structural mezzanine in place, they needed a solution that would seamlessly integrate with the mezzanine’s layout while ensuring it adhered to strict load requirements of the mezzanine.
To address these requirements, Storage Coordinators delivered a High-Density Mechanical Assist Mobile Shelving System—a cutting-edge solution that dramatically increased storage capacity and streamlined their stockroom operations. Traditional shelving wastes space because such a large percentage of floor space is wasted by aisles. Mobile Shelving can increase space by delivering the same capacity as static shelving in 1/2 the floorspace OR it can double the storage capacity of existing floor space.
Challenges
The key challenge was designing a high-density mobile shelving system that would maximize storage capacity on the mezzanine without overloading its weight limits. As the mezzanine was installed by another contractor, Storage Coordinators, Inc. had to ensure their design was structurally sound and would meet all load requirements.
The project also presented several technical and logistical hurdles:
- Mezzanine Load Compliance: The mezzanine’s 160 PSF load limit required precise engineering to ensure the live loads of the shelving system and stored materials adhered to its capacity.
- For reference, the International Building Code (IBC) provides general capacity guidelines for mezzanines or work platforms and are measured in pounds per square foot (PSF). For example, 60 PSF for elevated platforms or offices, 125 PSF for light manufacturing storage warehouses, and 250 PSF for heavy manufacturing storage warehouses. But IBC code requires storage mezzanines to have a minimum rating of 125 psf.
- Space Optimization: Unlike traditional static shelving that requires fixed aisle space, these fixed aisles could be eliminated to make better use of the mezzanine footprint.
- Accessibility & Workflow: The system had to support a variety of bin and box sizes while maintaining smooth cart movement and ADA compliance.
- Tight Timelines: With material lead times of several weeks, the team had to ensure seamless coordination and rapid installation to install the system by September 2024 as the client requested.
Solution
After several site visits, consultations and various design iterations with the client, the design team at Storage Coordinators, Inc. developed a custom solution involving a High-Density Mechanical Assist Mobile Shelving System. These systems were paired with Rivet Style Boltless Shelving. Here are some key aspects of the solution:
- Custom Design and Layout:
- Storage Coordinators’ design team developed a layout that maximized the client’s storage capacity while maintaining easy access to all of their stored items.
- A combination of 48″ and 60″ wide shelving units were used each with 6 shelf levels with wire decking and a capacity of 500 lbs. per shelf, ensuring strength and durability.
- Engineering and Structural Consideration:
- Storage Coordinators performed engineering calculations to ensure that the system’s total weight would not exceed the load-bearing capacity of the structural mezzanine. The system design was mindful of both the shelving weight and the weight of the stored materials.
- A structural engineer approved the design, ensuring the mezzanine would safely accommodate the fully loaded shelving system.
- Custom Integration:
- The (2) mechanical assist systems consisted of 7 mobile carriages, 231 linear feet of track, and an entry ramp and trim, designed specifically for the client’s operational needs.
- The solution included custom ADA-compliant ramps and plywood decking to facilitate the smooth movement of carts in and out of the mobile shelving aisles, ensuring an efficient workflow for their team.
- Multiple Manufacturer Integration:
- Storage Coordinators sourced materials from five different manufacturers to meet the specific requirements of the project. Material was all consolidated at Storage Coordinators’ facility for preparation and delivery. This allowed for a fully customized, high-quality solution that met the client’s storage goals.
- Delivery and Installation:
- The entire system was delivered to their facility using Storage Coordinators’ own trucks and crew, which minimized the risk of damage during transit and ensured all material arrived on-site as needed for the installation.
- Installation took just five days, carried out by Storage Coordinators’ expert installation crew, this minimized downtime and disruption for the client.
System Specifications
- (114) units of Boltless Rack Shelving units with 6 Levels & Wire Deck
- 48″ x 18″ x 84″ High
- 60″ x 18″ x 84″ High
- 2 Mobile Systems consisting of:
- (7) Mobile Carriages, 30′ Long x 26″ Wide
- (7) Mechanical Assists with Shaft Drives
- (231) Linear Feet of Track & Shim
- 5/8″ Plywood Decking with Entry Ramp and Trim
- ADA Deck/Ramp
- Total weight of mobile system is 18,245 lbs. (not including product)
Benefits and Results
The high-density stockroom project was completed on time and within budget. The client was highly satisfied with the results. The custom-designed high-density mobile shelving system completely transformed what used to be dead space in their facility into a high-capacity stockroom. The system maximized their storage capacity while ensuring seamless integration with their mezzanine. The mobile system provided easy access to stored items.
- Increased Storage Capacity: The mobile system doubled the capacity of their stockroom, allowing the client to store more within their existing footprint.
- Enhanced Workflow: Smooth cart movement and open style Rivet shelving provides easy access to bins and boxes and streamlined day-to-day operations.
- Cost Savings: The solution avoided the need for expensive facility expansions or offsite storage.
- Reliability & Safety: Durable materials and an engineered design ensured long-term performance and structural compliance.
Why High-Density Mobile Shelving?
- 📦 High-Density Storage: Doubled the storage capacity of their stockroom, allowing the client to store more in their existing footprint.
- 💡 Cost Savings: Eliminated the need for costly expansions or offsite storage—maximizing the value of their new stockroom.
- 🔧 Versatility: Designed to store a wide variety of items, from small tools to bulkier equipment.
- ✅ Safety and Security: ADA-compliant ramps with decking for smooth cart access, and structural engineer-approved designs for mezzanine load compliance.
- 🛑 Eliminates Wasted Space: By mounting shelving on wheeled carriages that travel on rails, the wasted space from fixed aisles is be eliminated, freeing up precious floor space for more productive uses.
Key Takeaways
This project is a prime example of the turnkey storage solutions that Storage Coordinators, Inc. offers, from design and engineering to project management and installation. By coordinating with multiple manufacturers and handling every aspect of the process in-house, Storage Coordinators provided a fully customized, high-density storage solution that exceeded client expectations.
Services Provided:
- Custom stockroom layout design and engineering
- High-density mobile shelving systems
- Freight coordination using in-house trucks
- Professionally installed by expert shelving installation team
Key Features:
- High-Density Mechanical Assist Mobile System
- White Melamine End Panels
- Rivet Style Boltless Shelving with low-profile double-rivet beams and wire deck
- ADA-compliant ramps and entry system
- System design approved by structural engineer
Transform Your Storage Space
Whether you manage a warehouse, manufacturing facility, or stockroom, Storage Coordinators specializes in high-density storage solutions that:
Maximize storage space
Eliminates wasted space caused by fixed aisles
Improves workflow efficiency
Reduce costs
Explore how we can optimize your operations today. Contact one of our storage experts today to discuss your storage challenges.
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