Project Overview
This 4,800 m² FMCG distribution center with an 8.5 m clear height was operating on block-stacked pallets. The existing approach created three recurring problems:
- FIFO access difficulty — upper pallets had to be moved before reaching older stock
- Low vertical utilization — only 3.5 m of the 8.5 m height in use
- Unknown floor load limits — no documentation on point load ratings
Sahawatthanakit (1988) was engaged for a full-scope EPC: layout design, procurement, and installation of a Selective Pallet Rack system.
Design Process
Step 1 — Site Survey
- Measured clear height, column spacing, and floor levelness
- Reviewed floor slab specification and point load rating documentation
- Mapped door locations, fire suppression sprinkler head positions, electrical conduit runs
Step 2 — Pallet Profile Analysis
The team analyzed the customer's 320-SKU inventory profile:
| Category | Weight per Pallet | Share |
|---|---|---|
| Light goods (<500 kg) | 800 positions | 67% |
| Medium goods (500-800 kg) | 300 positions | 25% |
| Heavy goods (>800 kg) | 100 positions | 8% |
Step 3 — Layout Design
- Selective Rack chosen over Drive-In — customer required FIFO compliance and random-access picking
- Zone A/B/C segmentation by picking frequency
- 3.2 m aisle width designed for the existing counterbalance forklift fleet
- 6 beam levels per upright column — utilizing 7.5 m of the 8.5 m clear height
Step 4 — Engineering Analysis (ANSI MH16.1)
- Computed Uniformly Distributed Load (UDL) per beam level
- Verified upright capacity against column spacing and load combinations
- Issued load notice plates for every bay as required by ANSI MH16.1
Installation
| Detail | Specification |
|---|---|
| Rack system | Selective Pallet Rack — teardrop connection |
| Upright height | 8.2 m |
| Beam levels | 6 per bay |
| Bay width | 2.7 m standard |
| Beam load capacity | 1,200-2,500 kg per level (by zone) |
| Column guards | Steel rack protectors on all perimeter uprights |
| Safety netting | Rear-face netting on all sections |
| Load notices | Installed on every bay per ANSI MH16.1 |
| Installation duration | 14 working days |
Outcomes
| Metric | Result |
|---|---|
| Pallet positions | 1,200 (vs. 720 before — +67%) |
| Vertical utilization | From 3.5 m → 7.5 m |
| Wasted floor area reduction | 35% |
| Installation duration | 14 working days |
| Installation incidents | Zero |
| ANSI MH16.1 compliance | Every bay — load-analyzed and certified |
Why the Customer Chose Us
- Designed for the operation, not just filled with racks — traffic flow, pick-zone layout, and forklift path were engineered around actual processes
- Engineering-backed confidence — formal load analysis addressed the client's floor-loading concern before any steel was ordered
- Single-contractor EPC — design, procurement, installation, and load notices from one team
- On-schedule delivery — warehouse continued receiving goods throughout installation
Related Services
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