One of our long-standing customers approached us to enhance efficiency and productivity in their warehouse. Over the years, we gained valuable insights into their operations. Therefore, we developed a detailed User Requirement Specification that shaped the Functional Design Specification, ensuring the new installation met our customer’s objectives.
Optimizing Racking Layout
The project required a revised racking layout to improve movement and picking efficiency. By adjusting the aisle width, we enabled the use of articulated trucks. Since many staff members are trained to operate these trucks, the changes allowed quicker order fulfillment.
Upgrading to Dexion P90
We replaced the old Dexion MK3 system with the Dexion P90. The P90 frames’ galvanized finish reflects light throughout the warehouse, enhancing visibility. Additionally, the 1100mm deep frames accommodate euro and chep pallets, while the 2700mm clear entry beams allow for easy storage of overhanging loads. Dexion pallet racking systems comply with all relevant design codes including FEM, EN, and SEMA standards.
Incorporating Safety Accessories
The redesign included multiple racking accessories. We installed Mesh Decks at all beam levels to bolster loading and unloading safety. For many customers, timber or mesh decks have become mandatory for pallet racking installations. To protect the racking uprights from impact damage, we fitted Rack End Barriers, preventing pallets stored at the ends from damaging the end frames. We also added polymer guards to all aisle-facing uprights to safeguard against pallet or forklift damage.
Enhancing Warehouse Lighting
We updated the warehouse lighting by installing Racking Low Bay LED units. These improvements make it easier and safer to load and unload pallets. The compact, powerful LED lights provide 15,000 lumens per unit, significantly brighter than the old sodium units.
Managing Project Logistics
As a COMAH site, we needed a phased approach to complete this project. We removed fixed fire protection from the existing racks before dismantling them. Following this, we replaced the lighting, cleaned and sealed the floor, and installed the new racking. Finally, we refitted the sprinklers and reloaded the pallets.
“We were very impressed with 2h Storage from start to finish on this project. The attention to detail in the early design stages and their flexibility during installation helped us achieve our goals. This is why we have partnered with 2h for many years,” said AW, Warehouse Manager.
Comparing Racking Systems
Old Dexion MK3 System
New Dexion P90
