How many layers should Case Warehouse Storage stack?

Five, for 1850 mm overall. Above that a ladder is needed and the pick rate halves.

1200 x 800 or 1200 x 1000 pallets?

Follow the footprint. Four cases fill the 800 deck but use 80 percent of the 1000 deck.

Is a 3 m aisle wide enough?

Only for a reach truck. A counterbalance needs 3.2 m, and 200 mm goes to the line.

Can cases go straight on the floor?

Within five layers, on a slab flat to 5 mm over 3 m.

Why must labels face the aisle?

So the driver reads layer count and weight from 3 m and leaves in one lift.

Case Warehouse Storage: Stack Height, Pallets and Aisle Width

Quick answer: Case Warehouse Storage is planned from the pallet outward. A 600 x 400 x 340 mm case fits four per layer on a 1200 x 800 mm pallet; five layers give 1850 mm and 146 kg. A 500 kg dynamic rating covers it, and a counterbalance truck needs a 3.2 m right-angle aisle.

Three Numbers First: Layers, Height, Floor Load
Pallet Size and Rating
Aisle Width and Turning Radius
ABC Zoning and Dispatch Distance
Wrap, Labels and Monthly Checks
FAQ

1. Three Numbers First: Layers, Height, Floor Load

Case Warehouse Storage starts with one pallet. A 600 x 400 x 340 mm case at 6.2 kg fits four per layer on a 1200 x 800 mm pallet, so five layers hold twenty.

Height is case height times layers plus a 150 mm pallet, giving 1850 mm. Manual reach stops near 1700 mm, and above it a pick stretches from 40 to 70 seconds.

Floor load runs at 152 kg per square metre from a 146 kg pallet, inside a 3000 kg per square metre slab; the real check is the 900 kg through one wheel.

Parameter	Value
Cases per layer	4
Layers	5
Cases per pallet	20
Goods per pallet	124 kg
Load height	1850 mm
Pallet gross	146 kg

2. Pallet Size and Rating

In Case Warehouse Storage the pallet follows the case footprint. Four cases use only 1200 x 800 of a 1200 x 1000 deck; a 1200 x 800 pallet fills completely and adds a fifth more stock per bin.

Depth costs. A shallow pallet on 1000 mm racking sits 200 mm short at the face, drivers judge the gap by eye, and beams take dents in six months.

Rate the worst case: five layers need 200 kg dynamic, but a second pallet on top passes 300 kg static through four corner blocks, and damp wood loses a fifth.

Size (mm)	Cases	Efficiency	Dynamic
1200 x 800	4	100%	500 kg
1200 x 1000	4	80%	1000 kg
1200 x 1200	6	96%	1200 kg
1400 x 1200	6	86%	1500 kg

3. Aisle Width and Turning Radius

A right-angle aisle measures turning radius plus fork length plus 150 mm. A 1.5 tonne counterbalance turns in 1950 mm, giving 3.2 m; a reach truck turns in 1650 mm, needing 2.9 m.

In Case Warehouse Storage the usual failure is an aisle wide on paper and eaten by the load. The stack face stands 100 mm off a 100 mm line, leaving 2.8 m from a 3.0 m line.

Chamfer inside corners at 1.5 m and repaint the yellow line every three months.

Truck	Radius (mm)	Right angle (mm)
Counterbalance 1.5 t	1950	3200
Reach truck 1.5 t	1650	2900
Stand-on stacker	1450	2750
Hand pallet truck	1350	2000

4. ABC Zoning and Dispatch Distance

In Case Warehouse Storage, location value decays with distance. Class A sits within 15 m of the dispatch door, B within 30 m, C within 45 m. A truck averages 1.7 m per second indoors, so a 30 m round trip costs 35 seconds.

At 60 pallets a day with A taking 60 percent, moving that block from 45 m to 15 m saves about 36 minutes a shift.

Zone	Turnover	Distance	Bins
A	7 days or less	15 m	30%
B	8 to 30 days	30 m	40%
C	Over 30 days	45 m	25%
Inspection	Variable	Receiving	5%

5. Wrap, Labels and Monthly Checks

Case Warehouse Storage relies on film for restraint, not dust. Use 500 mm film at 23 microns, three turns at the deck and two at the top, with 50 percent overlap.

Labels face the aisle at 1200 to 1500 mm: product, case count, gross weight, date.

Monthly checks cover a stack past 1850 mm, film loose in a full turn, and a pallet foot split beyond 100 mm, leaving the stack on film alone.

Conclusion

Case Warehouse Storage runs on one chain of numbers: fill the pallet from the case footprint, cap the stack at five layers and 1850 mm, size the aisle at 3.2 m, then place bins at 15, 30 and 45 m by turnover. Keep the stack face 100 mm off the yellow line and scrap a pallet foot split past 100 mm, and floor area turns into usable bins. That is what Case Warehouse Storage planning is for.

This article discusses only the container (case body) side of specifications and design intent, and does not cover any handling, loading or use of the contents.